Royal Enfield Bullet 500 EFI (2011) Handleiding

Royal Enfield Motor Bullet 500 EFI (2011)

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FOREWORD

Welcome to the Royal Enfield family.

Royal Enfield motorcycles are being manufactured by us since 1955 with state of the art technology, while taking

care to maintain the traditional Classic looks.

The motorcycle that you have just bought, confirms to United States Environment Protection Agency laws, Federal

Motor Vehicle Safety Standards and California Air Resources Board regulations. (Applicable only for motorcycles

sold within the state of California.)

This Owner’s manual will help you to acquaint with the important aspects of operation, care and minor maintenance

of your new Royal Enfield motorcycle. We recommend that you read this manual carefully, before using the

motorcycle which will help you to maintain your motorcycle in top riding condition. Major repairs are detailed in

the Royal Enfield service manual. Such major repairs require the attention of a skilled technician and use of

special tools and techniques. Your Royal Enfield dealer has the facilities, experience and genuine Royal Enfield

spare parts necessary to render those valuable services in a correct procedure.

FOREWORD

We have also provided several vital safety information for the rider and for the care and safety of the motorcycle.

Please read and follow these carefully for safe riding and for maximum riding pleasure. Please ride cautiously,

safely and within the law. Always wear a helmet, good riding goggles and proper riding clothes while riding the

motorcycle. Please insist and ensure that your pillion rider also follows these guidelines while riding with you.

Log on to the exciting world of Royal Enfield web site: www.royalenfield.com to get to know more about us and

exciting news from time to time.

We wish you many years of riding pleasure with your Royal Enfield motorcycle.

NOTICE

Because of continuous improvements in the product and changes that may occur in the manufacturing process,

subsequent to printing of this manual, it is possible some instructions, illustrations, pictures or designs found

within this manual may differ from those actually in the motorcycle. However the technical information found

within this manual was correct at the time it was approved for printing.

Royal Enfield team

Chennai, India.

otherwise dealt, without the express permission in writing of Eicher Motor Limited, Royal Enfield Unit.”

Part No. 584039/a /Qty. 250/ January ‘11

REPORTING SAFETY DEFECTS

If you believe your motorcycle has a defect which could cause a crash and result in serious injury or loss of life,

you should immediately contact the National Highway Traffic Safety Administration (NHTSA) in addition to notifying

Classic Motor works, 1405 Cannon Circle Suite 12, Faribault, MN 55021. Toll Free: 1 800 201 7472

If NHTSA receives similar complaints, it may open an investigation and if it finds that a safety defect exists in a

group of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in any

individual problems between you, and your dealer or Classic Motor works.

To contact NHTSA you may call the Auto Safety Hotline toll-free within the United States

on 1-800-424-9393 or write to: NHTSA, 400 Seventh Street SW, Washington, DC 20590.

You can also obtain other information about motor vehicle safety from the hotline.

IMPORTANT

United States Environment Protection laws, Federal Motor Vehicle Safety Standards

and California Air Resources Board (Applicable only for motorcycles sold within the

state of California.) strictly prohibits tampering with the Exhaust Emission Control, Noise

Control and Evaporative Emission Control systems:

We would like to emphasize that any repairs to the induction, emission, exhaust and evaporative systems must

be performed only by an Authorized Royal Enfield Dealer so that the motorcycle confirms to the United States

Environment Protection laws, Federal Motor Vehicle Safety Standards and California Air Resources Board

regulation (Applicable only for motorcycles sold within the state of California.)

It is the responsibility of the Owner / User of the motorcycle to read this manual carefully and to comply with the

safety guidelines, operating instructions, and periodical maintenance instructions given here. Keep this manual

in a convenient place for easy reference. DO NOT use the motorcycle until you have become familiar with this

motorcycle and after reading and understanding this manual completely. Inc ase you nee d an y furth er

clarifications, please contact an Authorized Royal Enfield Dealer, nearest to you, for assistance.

If your motorcycle is being used by a friend, relative, or any other person, it is your responsibility to make certain

that they have completely understood the operating procedures of the motorcycle, and the contents in this

manual with particular reference to the safety aspects, before riding your motorcycle.

This motorcycle is designed for NORMAL ON ROAD USE ONLY. Operation in off-road usage in some areas may

be illegal and could be dangerous. Please obey local laws and regulations.

In the event of your motorcycle being sold to another person, it is your responsibility to hand over this manual

along with the motorcycle to the new owner.

SAFETY DEFINITIONS

Statements in this manual preceded by the following words are of special significance:

WARNING

Indicates a potentially hazardous situation, which if not avoided, could result in an accident causing

serious injury or loss of life.

CAUTION

Caution with the safety alert symbol, indicates a potentially hazardous situation, which if not avoided,

may result in minor or moderate injury leading to disability.

Caution

Caution without the safety alert symbol indicates a potentially hazardous situation, which if not avoided, may result in

damage to the motorcycle and its rider, property etc.

All images in this manual are only for reference and to explain the relevance. They may not be exactly the

same in the motorcycle you own. Technical specifications are subject to change without prior notice.

IMPORTANT NOTICE !

CONTENTS

PERSONAL & MOTORCYCLE INFORMATION ... 10

SAFE OPERATING RULES .................................. 11

ACCESSORIES AND CARGO ............................. 18

RULES OF THE ROAD ......................................... 20

TECHNICAL SPECIFICATIONS ........................... 22

-Engine ......................................................... 22

- Ignition System ............................................ 23

- Transmission ............................................... 23

- Electricals .................................................... 25

- Chassis ....................................................... 26

- Dimensions ................................................. 27

- Weights ....................................................... 27

- Performance ................................................ 27

MOTORCYCLE IDENTIFICATION NUMBER ....... 28

ENGINE NUMBER DETAILS ................................ 30

KEY PARTS LOCATION ....................................... 31

- Top View ...................................................... 31

- Right Side View ........................................... 32

- Left Side View ............................................. 33

OPERATION OF CONTROLS .............................. 34

- Ignition Switch ............................................. 34

- Dip Switch ................................................... 35

- Head lamp Day flash ................................... 35

- Supplementary Engine Stop ....................... 36

- Engine Start Switch ..................................... 36

- Turn Signal Switch ...................................... 37

- Manual Bi Starter ........................................ 38

- Horn ............................................................ 38

- Fuel Tank Cap ............................................. 39

CONTENTS

SIDE VIEW MIRRORS .......................................... 40

PRE OPERATIONAL CHECKS ............................ 41

RUNNING IN ......................................................... 42

EVAPORATIVE EMISSION IMPORTANT NOTE .. 44

- California Air Resources Board,

Emissions Regulations ................................ 44

FUEL GAUGE, MALFUNCTION INDICATOR &

ROLL OVER SENSOR ......................................... 45

STARTING ............................................................ 46

GEAR SHIFTING .................................................. 50

PARKING .............................................................. 53

- Center Stand ............................................... 53

- Side Stand .................................................. 53

TOOLS & SPARES KIT ........................................ 54

RECOMMENDED LUBRICANTS ......................... 55

PRE OPERATIVE CHECKS ................................. 56

PERIODICAL MAINTENANCE ............................. 57

MINOR MAINTENANCE TIPS .............................. 61

- Control Cables, Handlebar lever pivots,

Centre /Side stand pivots ............................ 61

- Oil Level Inspection ................................... 61

- Engine oil change ...................................... 62

- Spark Plug .................................................. 63

- Brake fluid .................................................. 63

- Inspection of tires and wheels .................. 64

- Tire pressure .............................................. 64

- Front Wheel removal ................................. 65

- Front Wheel reassembly ............................ 66

- Rear wheel removal ................................... 67

- Rear wheel reassembly ............................. 68

CONTENTS

ADJUSTMENTS ................................................... 69

- Clutch Cable play....................................... 69

- Drive Chain tension ................................... 70

- Rear Brake pedal height ............................ 71

- Rear Brake ................................................. 71

- Chain Lock Fitment .................................... 72

- Rear Shock Absorbers............................... 73

- Battery Maintenance .................................. 74

- Battery removal from the Motorcycle ........ 74

- Battery assembly on Motorcycle ............... 75

- Head Lamp sealed beam .......................... 76

- Tail Lamp bulb ............................................ 76

- Trafficator bulbs ......................................... 77

- Fuse ............................................................ 78

WASHING PROCEDURE ..................................... 79

- Precautions ................................................ 79

- After washing ............................................. 79

STORAGE PRECAUTION .................................... 81

- Preparing the motorcycle for reuse ......... 82

SAFETY RIDING TIPS .......................................... 83

- Riding Dress .............................................. 83

- Sitting posture ........................................... 83

- Braking ...................................................... 83

LONG TRIP PRECAUTONS ................................. 84

- Checks prior to the commencement ........... 84

- Checks after every 1500 kms .................. 84

- Items to be carried .................................... 84

CONTENTS

WIRING DIAGRAM.................................................85&86

- Complete Circuit ....................................... 85

- Contact Diagram ....................................... 85

- Ignition Circuit ........................................... 86

- Starter & Charging Circuit ........................ 86

TROUBLE SHOOTING ......................................... 87

- Engine fails to start .................................... 87

- Engine misfiring ......................................... 88

- Engine starts, but runs irregularly & stops ... 88

- Poor pickup ................................................ 89

- White / blue smoke .................................... 89

- Engine overheating .................................... 90

- Excessive fuel consumption ...................... 90

- Brakes poor ................................................ 91

- Motorcycle wobbles ................................... 91

- Electricals ................................................... 92

- Electronic Fuel Injection ............................ 93

WARRANTY .......................................................... 94

EMISSION CONTROL SYSTEM Warranty .......... 96

NOISE CONTROL SYSTEM WARRANTY ........... 98

EVAPORATIVE EMISSION CONTROL

SYSTEM WARRANTY (Applicable only

for the state of (California) .................................. 100

SERVICE MAINTENANCE RECORD ................... 102

NOTES .............................................................. 108

PERSONAL & MOTORCYCLE INFORMATION

Name

Door No./ Street

Locality

City Country

Contact Res : Off :

Mobile : Email :

Licence No. Valid till :

Model Color :

Engine No.

VIN. No.

Tire make Front : Rear :

Number

Battery make Battery No.

Sold by

Date of Sale

SAFE OPERATING RULES

Royal Enfield motorcycles are designed to serve as a

means of personal transport, and for on road use only.-

It is not meant to be used as an off-road motorcycle.

WARNING

Using the motorcycle for Off-road purposes

could lead to loss of control which could result in an

accident causing serious injury or loss of life.

Before operating your new motorcycle, it is your

responsibility to carefully read and follow the operating

and maintenance instructions detailed in this manual

for your own safety, your motorcycle and that of others

Before starting the motorcycle, check for proper

operation of brakes, clutch, gear shift, electrical

components, handle bar controls, tire pressures, fuel

and oil levels.

Know and respect the rules of the road. Be a safe

rider for your own safety and for other road users.

Fuel / Refueling

Royal Enfield motorcycles are designed to perform

best with unleaded gasoline only. Use a good quality

unleaded gasoline of 87 RON or higher. If ‘knocking’

or ‘pinging’ occurs at a steady engine speed under

normal load, use a different brand of gasoline or

gasoline which has a higher octane rating.

WARNING

Do not use leaded gasoline in this motorcycle.

It will cause serious damage to the internal of the

engine, exhaust emission system and the motorcycle

will not meet the emission norms. Using leaded

gasoline will also render the warranty void.

It is illegal to use leaded gasoline as it is known to

cause serious health problems

Fuels containing methanol should not be used as it

can cause damage to the fuel system components

SAFE OPERATING RULES

WARNING

Gasoline is extremely flammable and highly

explosive under certain conditions. Any fuel leak,

spillage, or negligence of adhere to safety norms

may lead to a fire hazard or explosion, which could

cause damage to property, injury to persons or

loss of life. When refueling your motorcycle,

please exercise utmost caution and carefully

observe the following rules:

Turn the ignition switch to the ‘OFF’ position

Open the fuel filler cap slowly. This will help to release

any pressure that may have built up in the fuel tank.

DO NOT smoke and please ensure that there are

no open flames or sparks near the motorcycle, when

refueling OR servicing the fuel system.

Refuel in a well ventilated area.

DO NOT use a mobile telephone. Switch OFF

mobile telephones and any other electrical and

electronic devices including any appliances with a

pilot light.

DO NOT fill the fuel tank to its brim. Please fill fuel

only till the bottom of the filler neck insert so as to

leave air space for fuel expansion, inside the fuel

tank. Overfilling the tank can lead to fuel spillage.

Avoid filling the tank in rainy or dusty conditions

where airborne material can contaminate the fuel.

Contaminated fuel may cause damage to fuel

system components.

After refueling, please ensure the fuel filler cap is

closed firmly and correctly.

WARNING

Fuel spilled on the floor or on motorcycle

tires will reduce the tire’s ability to grip the road.

This can result in dangerous riding condition,

potentially causing loss of control and could result

in an accident If fuel is spilled, thoroughly clean

up the spillage immediately. Take care not to spill

any fuel on the engine, exhaust pipes, rubber parts

or any other part of the motorcycle.

Do not store motorcycle with gasoline in the tank,

within your home or garage where open flames,

pilot lights, spark or any appliance with a pilot

light, electric motors are present. Inadequate

safety precautions could cause an explosion or

fire and could result in damage to property, serious

injury or loss of life.

SAFE OPERATING RULES

Tires & Suspension

Please inspect and ensure tires are seated evenly &

properly in the rims. Maintain the recommended tire

pressures as it is very important for riding stability. Pay

strict attention to loose and / or broken spokes Ensure

the front and rear wheels are correctly aligned. Check

spokes for correct tightness in the rims and free

movement of steering system.

Inspect the tires thread condition periodically and replace

worn out tires with approved make only. Failure to do so

can lead to improper balance, poor stability, poor

handling, and abnormal tread wear.

Please replace tires which are punctured or damaged.

Small punctures in the tread area may be repaired from

within the tire. The motorcycle should not be driven over

40 MPH (60 Kmph) for the first 24 hours and over 55

MPH (90 Kmph) thereafter with a repaired tire.

WARNING

In emergency situations, please ride slowly

with least possible load until the tire is permanently

repaired or replaced. Failure to heed to this warning

could result in serious injury or loss of life.

Regularly inspect front forks, rear shock absorbers and

rear suspensions for any wear, looseness / side play, oil

leaks etc. Replace worn parts. Worn parts can adversely

affect stability and handling.

WARNING

DO NOT operate motorcycle with a loose, worn

or damaged steering system, including the front and

rear suspension system. Contact your dealer for

repair of steering or suspension system. Damaged

steering or suspension components may adversely

affect handling which could result in serious injury

or loss of life.

Running in

A new motorcycle must be operated according to the

special break-in-procedure. (See BREAK-IN-THE FIRST

300 Miles (500 Kms) 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 condition

DO NOT exceed the legal speed limit or drive too fast for

existing conditions. Always reduce speed when poor

driving conditions exist. High speed increases the

influence of any other condition affecting stability and

increases the possibility of loss of control.

SAFE OPERATING RULES

NOTE

If you are an inexperienced rider we recommend

that you obtain fo rma l trai nin g on co rre ct

mo torcy cle ridi ng tec hniqu es and become

thoroughly familiar with the operation of your

particular motorcycle. New riders should gain

experience under various conditions while driving

at moderate speeds.

WARNING

Avoid over speeding and never travel over

the speed limit. Excessive speed may cause loss

of control and could result in an accident causing

serious injury or loss of life.

DO NOT exceed 70 MPH (110 Kmph) riding solo.

DO NOT exceed 55 MPH (90 Kmph) when carrying a

passenger and/or cargo.

Pay strict attention to road surfaces and wind

conditions. Any two wheeled motorcycle may be

subject to the following upsetting forces:

 Wind blasts from passing trucks.

 Rough uneven road surfaces.

 Slippery road surfaces.

These forces may affect the handling characteristics

of your motorcycle. If this happens, reduce speed and

guide the motorcycle with a relaxed grip to a controlled

condition. Do not brake abruptly or forc e 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.

Safe motorcycle operation requires alert mental

judgment combined with a defensive driving attitude.

DO Not allow fatigue, alcohol or drugs to endanger

your safety OR that of others.

Wear an approved helmet, clothing, and foot gear

suited for riding a motorcycle. Bright OR light colors

are best for greater visibility in traffic, especially at

night. Avoid loose, flowing garments and scarves.

When carrying a pillion rider, it is your responsibility

to instruct them on proper riding procedures.

SAFE OPERATING RULES

DO NOT allow oth er individuals, under any

circumstances, to operate your motorcycle unless you

know they are experienced, licensed riders and are

thoroughly familiar with the operating conditions of your

motorcycle

Additional electrical accessories and equipments may

overload the motorcycle’s electrical system and will result

in system and/or component failure.

Maintain your motorcycle in proper operating condition

in accordance with the Maintenance intervals chart in

this Owner’s Manual.

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. Contact your

Royal Enfield dealer for further details

WARNING

For your personal welfare, all the listed service

and maintenance recommendations should be

performed. Lack of regular maintenance at the

suggested intervals may affect the safe operation of

your motorcycle, which could result in serious injury

or loss of life.

WARNING

Consult your Royal Enfield Dealer regarding

any questions or problems that occur in the operation

of your motorcycle. Failure to do so may aggravate

an initial problem, cause costly repairs, jeopardize

your personal safety and could result in serious

injury or loss of life.

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. Failure to wear proper or

protective clothing could result in serious injury.

WARNING

Exhaust gases contains poisonous carbon

monoxide and chemicals, known to cause Cancer, Birth

Defects or other reproductive defects. DO NOT INHALE

exhaust gases. Do not stay inside a closed garage after

parking the motorcycle as the residual fumes from the

exhaust can contain harmful gases. Failure to heed to

these warnings can result in loss of life.

SAFE OPERATING RULES

WARNING

Motorcycle batteries contain lead and lead

components, acids and chemicals known to cause

cancer, birth defects or other reproductive harm.

Exercise extreme caution while handling a battery.

Wash hands thoroughly whenever a battery is

handled.

This motorcycle is not designed to tow a trailer or be

used with a sidecar. It is designed to be used as a

two wheeler, for carrying a rider and a pillion.

WARNING

Towing a trailer may cause loss of control

of the motorcycle in the front, reduced braking

efficiency, tire overloading and unstable handling,

leading to an accident resulting in serious injury

or loss of life.

Using the motorcycle with a side car could cause

loss of control, resulting in an accident which may

cause serious injury or loss of life.

WARNING

DO NOT tow a disabled motorcycle. The

steering and handling of the disabled motorcycle

will be impaired due to the force of the towline. If a

disabled motorcycle must be transported, use a truck

or a trailer. Towing a motorcycle may cause loss of

control of the motorcycle in the front, leading to an

accident resulting in serious injury or loss of life.

DO NOT exceed the Gross Vehicle Weight Rating

(GVWR) of your motorcycle which is provided in the

information plate, located on the frame down tube.

(GVWR is the total sum of the weight of the motorcycle,

accessories, rider, pillion and cargo that may be safely

carried).

WARNING

Exceeding GVWR may lead to instability of the

motorcycle, leading to an accident and result in

serious injury or loss of life.

SAFE OPERATING RULES

WARNING

Use only genuine Royal Enfield replacement

fasteners tightened to the proper torque. We

caution you against the use of certain nonstandard

parts such as aftermarket and custom made

fasteners which may not have specific strength,

finish and type requirements to perform properly

in the assembly and its environment. The use of

any nonstandard parts, including fasteners, could

result in serious injury or loss of life.

WARNING

Royal Enfield cautions you against the use

of certain nonstandard parts such as aftermarket

an d cus tom ma de ex ten ded front for ks or

su spe nsions, wh ich ma y a dversely affect

performance and handling. Removing or altering

original parts may adversely affect performance

and could result in an accident causing serious

injury or loss of life.

ACCESSORIES & CARGO

Ro yal En fi eld canno t test an d mak e s pecif ic

re comme nda ti ons con cern in g spe cif ic or a

combination of accessories sold. Therefore, the rider

mu st be res pon sib le for sa fe ope ration of the

motorcycle when installing accessories or carrying

additional weight.

Please adhere to the following guidelines when

ca rryin g a pi lli on , c arg o o r whe n f ittin g a ny

accessories.

DO NOT exceed 70 MPH (110 km/h) when riding

solo.

DO NOT exceed 55 MPH (90 Km/h) when carrying

a pillion and/or cargo.

Keep cargo weight concentrated close to the

motorcycle and as low as possible; this minimizes

sudden shift in the motorcycle’s center of gravity.

Distribute weight evenly on both sides of the

motorcycle.

DO NOT load bulky items too far behind the rider

or add weight to the handlebars or front forks.

DO NOT exceed 5 pounds (2.3 kgs.) maximum

hanging load on either side of the motorcycle at

the rear end.

Recheck the cargo periodically to be sure it is

secured and will not shift while riding. Accessories

secured loosely may affect the r iding of the

mo tor cy cle an d a ff ec t th e s ta bi lity o f t he

motorcycle.

Large surfaces such as fairings, windshields,

backrests and luggage racks can adversely affect

handling of the motorcycle. Only genuine Royal

Enfield accessories, designed specifically for the

motorcycle model should be used with proper

installation.

WARNING

DO NOT load weight or install accessories

improperly on the motorcycle. Doing so may affect

th e mo torc ycl e’s s tab il it y, h an dli ng

characteristics, and safe operation and could

result in an accident causing serious injury or loss

of life.

RULES OF THE ROAD

Be sure all equipment required by Federal, State,

province and local law is installed and are in good

condition.

Be sure your license plate is installed in the position

specified by law and is clearly visible at all times.

Keep to the correct side of the road centre line

when meeting oncoming vehicle.

Watch for loose debris, such as dry or wet leaves,

slippery substances or loose gravel that can

hamper the stability of your motorcycle.

DO NOT leave the curb or parking area without

signaling. Be sure your way is clear to enter moving

traffic. A moving line of traffic always has the right

of way.

Always actuate your turn signals, and exercise

utmost caution when passing other vehicles going

in the same direction. Never try to pass another

vehicle going in the same direction at street

intersections, on curves, or when going up/or down

a hill.

While turning either right or left, watch out for

pedestrians, animals, as well as vehicles.

At street intersections always allow vehicles from

your right and left to pass before turning. DO NOT

assume you have the right of way.

Always signal when preparing to stop, turn or pass.

When intending to turn, signal at least 100 feet

(30.5 meters) before reaching the turning. Be close

to the center line (unless local rules require

otherwise), slow down and then turn carefully.

All traffic signs, including manual controls at

intersections, should be obeyed promptly. Slow

down at traffic signs near schools and caution signs

at railroad crossings.

Never jump a traffic light. When a change is

imminent from GO to STOP (or vice versa) at

RULES OF THE ROAD

intersections, slow down and wait for the light to

change to green. run through a yellow orNever

red traffic light.

 Ride at a safe speed that is consistent with the

type of road surface you are on. Pay strict attention

to whether the surface is

 Dry

 Oily

 Wet

 Icy

 DO NOT Exceed the legal speed limit or drive too

fast for existing conditions. Always reduce speed

when poor driving conditions exist. High speed

increases the influence of any other condition

affecting stability and increases the possibility of

loss of control.

WARNING

Avoid excessive speed and never travel at a

speed faster than the speed limit. Excessive speed

may cause loss of control of motorcycle, which

could result in loss of life or serious injury.

 Park your motorcycle on a firm 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.

ENGINE

Engine .............................................................. 4 Stroke, air cooled, single cylinder

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

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

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

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

Max. Power @ RPM ....................................... 20.3 Kw @ 5250 rpm

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

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

Engine Oil Tank Capacity .............................. 2.75 Litre

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

Engine Oil Grade ............................................ 15 W, 50 API, SL Grade, JASO MA

.......................................................................... ESTER - Semi Synthetic oil or equivalent.

Fuel Supply ..................................................... Electronic Fuel Injection

TECHNICAL SPECIFICATIONS

IGNITION SYSTEM

Ignition system ................................................ Digital Electronic Ignition

Spark plug gap ................................................ 0.7 mm

Spark plug ....................................................... WR7 DDC4 (BOSCH)

TRANSMISSION

Clutch ............................................................... Wet Multiplate

Drive Chain links ............................................. 101 pitches

Primary drive ................................................... Duplex Chain drive 3/8" pitch

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

TECHNICAL SPECIFICATIONS

Gear Ratios ..................................................... I - 3.063 : 1

II - 2.013 : 1

III - 1.522 : 1

IV - 1.212 : 1

V - 1.000 : 1

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

Secondary Drive ............................................. Chain Drive

Secondary ratio.............................................. 2. 235 : 1

TECHNICAL SPECIFICATIONS

ELECTRICALS

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

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

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

Head lamp ....................................................... 12V, 50/35 W

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

Turn signal ....................................................... 12V, 10W

Pilot lamp ......................................................... 12V, 2 W - 2 nos.

.......................................................................... 12V, 5 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 .................................................................. 12V, 2.5 Amp (Max.)

TECHNICAL SPECIFICATIONS

CHASSIS

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

Tire size Front ............................ 3.25 X 19 inches

Rear ............................ 3.50 X 19 inches

Tire pressure Front - Solo .................. 18 PSI

- Pillion ............... 20 PSI

Rear - Solo .................. 28 PSI

- Pillion ............... 30 PSI

Fuel tank capacity ............................ 14.5 + 1 Litres

Suspension Front ................... Telescopic, Hydraulic Damping

Rear .................... Swing arm with gas filled shock Absorbers

............................ with adjustable 5 step Spring tension load and

Gas Pressure ............................ 5-7 bar (70-100 psi)

TECHNICAL SPECIFICATIONS

DIMENSIONS

Length .............................................................. 2160 mm

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

Height ............................................................... 1050 mm

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

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

Ground clearance ........................................... 140 mm

WEIGHTS

Mass of vehicle in running order .................. 187 Kg

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

Max technical permissible mass ................... 365 Kg

PERFORMANCE

Maximum Speed ............................................. 82 MPH

NOTE

1. Values given above are for your guidelines only

2. In view of continuous improvements being done on our products, the specifications

are likely to change without notice

The VIN is a 17 digit number punched on the right side steering head tube and in the

information plate riveted to the frame down tube.

MOTORCYCLE IDENTIFICATION NO. - DETAILS

Sample VIN : ME3 FSV XX X X X XXX XXX

Manufacturer Make and Class code

Decipherable information

Capacity / Horse power

Check digit No

Year of Manufacture

Place of Manufacture

Engine No.

VIN

Punched on the steering head tube

Caution

It is illegal of tamper with the VIN / information plate as it is the only means of identification of the motorcycle.

MOTORCYCLE IDENTIFICATION NO. - DETAILS

VIN INFORMATION PLATE

Riveted on the frame down tube.

VEHICLE EMISSION CONTROL

INFORMATION

The engine number is punched on the left hand side Crankcase. It is the means of identification of the Engine and its

production details. Please do not tamper with the engine number as it is prohibited by law.

ENGINE NUMBER - DETAILS

ENGINE FAMILY

ENGINE CAPACITY

TYPE OF START

TRANSMISSION

FUEL FEED

BLANK FOR FUTURE USE

YEAR OF MANUFACTURE

PRODUCTION MONTH

PRODUCTION SERIAL Nos.

U 5 S 5 F 0AFX X X X X X

( 2009-9, 2010-A, 2011 -B,....)

(A - JAN., H - AUG., K - SEP., N - DEC.)

KEY PARTS LOCATION

1. Turn signal switch

2. Horn button

3. Clutch lever

4. Day flash switch

5. Head lamp dip switch

6. Manual Bi Starter

7. Ignition switch

8. Speedometer

9. Malfunction / Low fuel Indicator

10. Supplementary Stop Switch

11. Front brake lever

12. Accelerator

13. E-Start Switch

14. Fuel tank cap

TOP VIEW

KEY PARTS LOCATION

RIGHT SIDE VIEW

1. RH Trafficator front

2. Starter Motor

3. Brake Pedal

4. Kick Starter lever

5. Airfilter Box

6. RH trafficator rear

234

KEY PARTS LOCATION

LEFT SIDE VIEW

1. Trafficator front LH

2. Spark plug

3. Battery Cover

4. Electricals box LH

5. Rear Shock Absorber LH

6. Trafficator rear LH

7. Centre stand

8. Side stand

9. Gear change Lever

10. Horn

IGNITION SWITCH

OPERATION OF CONTROLS

ON OFF

OPERATION OF CONTROLS

Depress for Day Flash

DIP SWITCH

Low beam High Beam

HEAD LAMP DAY FLASH

OPERATION OF CONTROLS

SUPPLEMENTARY ENGINE STOP ENGINE START SWITCH

ON Depress

OFF

OPERATION OF CONTROLS

TURN SIGNAL SWITCH

Left OFF (Push to off) Right

CAUTION

Do NOT lubricate bar rel l ocks with

petroleum bas ed lu bricants or graphite.

Inoperative locks may result in damage to your

vehicle.

Lock the steering when leaving motorcycle parked.

Steering lock

Turn key clockwise to lock.

Caution

Protect your motorcycle against theft. After parking

your motorcycle, remove the ignition key from switch

and lock the steering head.

OPERATION OF CONTROLS

HORN

MANUAL BI STARTER

OPERATION OF CONTROLSOPERATION OF CONTROLS

FUEL TANK CAP (WITH KEY LOCKING

FEATURE)

FUEL TANK CAP (CALIFORNIA MODELS)

NOTE

Key can be removed only in locked position.

To Open:

Turn cap anti clockwise

To Close:

Locate cap and turn clockwise till click

Sound is heard

To Open:

Insert Key and Turn anti clockwise.

Cap will spring up.

To Close:

Press cap down with key in position

Key will return to locked position.

Remove Key.

SIDE VIEW MIRRORS

Your motorcycle is equipped with convex mirrors and has a curved surface. This type of mirror is designed to give

a wider rear view than a flat mirror; however the objects seen in this type of mirror will look smaller and farther

away than when seen in a flat mirror. Use care when judging the size or distance of objects seen in these mirrors.

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.

WARNING

Objects in mirrors are closer than they appear. Always use caution when judging distances of

objects in mirrors. Failure to judge correctly when seeing the objects on mirrors could cause an accident

resulting in serious injury or loss of life.

It is a good practice to check the following before using the motorcycle every time or once in a week

CHECK FOR:

1. Adequate fuel in the tank.

2. Operation and free play of front and rear brakes.

3. Free play and smoothness of all operating cables.

4. Free and smooth movement of the steering.

5. Battery electrolyte level.

6. Correct tire pressures and any cuts, cracks or sharp objects embedded in the tire.

7. Oil level: Top up if necessary. Do not overfill.

8. Operation of all electrical systems.

CAUTION

Failure to adhere to pre operational checks may cause the motorcycle to stall

when riding and lead to a potentially hazardous situation which, if not avoided, may

result in an accident and could cause minor or moderate injury.

PRE OPERATIONAL CHECKS

Proper running-in is very important for obtaining maximum life and performance of a new motorcycle. The following

guidelines explain proper running-in procedures.

Since the engine is brand new, it should not be loaded excessively for the first 1,000 Kms. (600 Miles). During the

first few hundred kilometers, the various parts in the engine wear and polish themselves to the correct operating

clearances. Driving with prolonged full throttle operation, or any high speed conditions might result in excessive

heating of the engine and cause abnormal wear of the moving parts and hence must be avoided.

1. 0 - 300 Miles (0- 500 Kms):

The recommended speed for the first 300 Miles (500 Kms) is 35 - 40 MPH (50 - 60 Kmph). During this period

avoid riding the motorcycle with full throttle opening. Stop the motorcycle for about 5 to 10 minutes to let it

cool down, after every hour of running. Vary the speed of the motorcycle regularly during running but avoid

using the motorcycle above 1/2 throttle opening position.

Caution

After covering the first 300 Miles. (500 kms), please replace the engine oil and filter.

RUNNING IN

2. 300 - 600 Miles (500 - 1000 Kms.):

The recommended speeds are 45 - 50 MPH (80 - 90 Kmph). Avoid riding 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. 600 Miles (1,000 kms) and beyond

Avoid prolonged full-throttle operation. Vary speed occasionally.

Caution

Royal Enfield engines are air-cooled and consequently require forced air cooling of the cylinder head and barrel

to maintain proper operating temperature. Extended periods of idling may over heat the engine, resulting in

serious engine damage.

DO NOT run the engine at extremely high RPM with clutch disengaged or transmission in neutral as it can cause

serious engine damage.

An engine running long distances at high speed must be given close attention to avoid over heating and possible

engine damage.

RUNNING IN

EVAPORATIVE EMISSION IMPORTANT NOTE

California Air Resources Board, Emissions

Regulations (Applicable for motorcycles sold in the

State of California)

Your Royal Enfield motorcycle is equipped with an

evaporative emission control system consisting of a

Canister, rubber hoses and connectors to comply with the

stringent California Air Resources Board (CARB) emissions

regulations, anti-smog standards.

The equipment does not have any serviceable parts for

the user to service. However in order to ensure that the

motorcycle is compliant, it is necessary to periodically

inspect the rubber tubes and connections for any leaks,

cracks, cuts or damage. Incase any of the above is noticed,

the motorcycle should be taken immediately to a nearest

Authorized Royal Enfield dealer for inspection and

necessary correction

The evaporative emission control system is covered under

warranty for 18,641 miles (30,000 Kms) OR 5 Years from

the date of sale of the motorcycle to the first customer.

As the vehicle owner, it is your responsibility to ensure that

the motorcycle is taken to the nearest Royal Enfield dealer

to carry out the required maintenance listed in the Owner’s

Manual. Royal Enfield recommends that you retain all

receipts covering maintenance on your motorcycle. It is

also your responsibility to present take your motorcycle to

a Royal Enfield dealer, if a problem in the evaporative

emission system. As the vehicle owner, you should also

be aware that Royal Enfield may deny your warranty

coverage if your vehicle or a part has failed due to abuse,

neglect, improper maintenance or unapproved

modifications. If you have any questions regarding your

warranty rights and responsibilities or if an authorized Royal

Enfield dealer cannot repair

your motorcycle or honor

your claim within a

reasonable period of time,

contact Royal Enfield for

assistance@ 312-569-

1075. If you are not satisfied

with the way in which a

warranty claim is resolved

by Royal Enfield, you may

write directly to:

California Air Resources

9480 Telstar Ave. Suite 4

El Monte, CA 91731

Director of Field Operations

Board Support Division (EI4-397F)

Environmental Protection Agency

401 M Street, S.W. Washington,

D.C. 20460

FUEL GAUGE, MALFUNCTION INDICATOR & ROLL OVER SENSOR

A Malfunction Indicator Lamp (MIL) is provided in the

small meter located on the right side on the head lamp

casing.

There are two indications in

this unit. Low fuel indication

& EFI Malfunction Indicator

Lamp (MIL)

When both the Ignition &

Engine kill switch is “ON”,

the MIL will glow for few

seconds and will switch OFF. This indicates that all

the functions of Electronic Control Unit (ECU) and

other sensors are working perfectly and the motorcycle

can be used. Incase of any malfunctioning of the ECU

or other sensors, the MIL will glow continuously. In

the event of any such phenomenon it is recommended

to take the motorcycle to a nearest Royal Enfield

authorized service station for inspection.

“ROLLOVER SENSOR”

Your motorcycle is fitted with a unique “Roll over

Sensor” This is a safety feature. In the event of an

accident OR if the motorcycle falls over on its side

with the engine running, the “Roll over Sensor” will

switch off Ignition and cut off fuel supply to prevent

the motorcycle from moving suddenly if it is in gear.

NOTE

To reset the Roll over sensor in the event the

motorcycle falls over. Please put the motorcycle in

its centre stand, switch off both the Ignition switch

and the stop switch on the handle bar RH control,

wait for a few seconds and switch ON the ignition

switch and the stop switch again. This will help to

RESET the “Roll over Sensor” and the engine can

be started.

STARTINGSTARTING

Turn ignition switch ‘ON’ Ensure ignition stop switch is in ‘RUN’ position

Ensure the side stand is in released position

Ensure gears are in neutral and neutral lamp is

glowing.

Depress Clutch Lever

STARTING

Caution

Never accelerate the engine immediately after

a cold start. The engine should be allowed to

operate at idling speed for a few minutes. This

will not only allow the engine to warm up but

will also help the engine oil to be circulated

and lubricate the moving parts inside the

engine. Failure to adhere to this may result in

damage to the engine.

Manual bi Starter

Depress Starter Button and release as soon as engine

starts.

NOTE

It may be necessary to depress and hold

the manual bi starter, after starting the

engine for the first time in cold mornings,

temperatures below 100C OR at high

altitudes, to prevent the engine from

stalling and to keep the idling RPM steady.

As soon as the engine sufficiently warms

up the RPM will raise at which time the

manual bi starter should be released.

STARTING

Warm up engine for 2 minutes - till idling is consistent.

Prior to riding, check to see if the low fuel indicator is

glowing continuously.

The low fuel indicator will glow continuously if the fuel

level in the tank in below 3.5 liters.

Caution

Please ensure the motorcycle is not used with the low

fuel indicator lamp “ON” continuously. It may not only

result in the motorcycle running out of fuel. BUT will also

cause serious damage to the fuel pump. Please ensure

fuel is filled up as soon as the low fuel lamp comes ON.

GEAR SHIFTING

CAUTION

The clutch must be fully disengaged before attempting to shift gears. Failure to fully disengage the

clutch may cause a jerky start and / OR stalling of the engine besides causing damage to transmission parts.

Warm up engine for 2 minutes - till idling is

consistent.

Pull clutch lever towards the hand grip.

Depress gear lever 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 start motorcycle in neutral. Always

move motorcycle in first gear.

Lift the gear lever with toe to engage 2nd and

higher gear.

Follow the same procedure for 3rd, 4th and 5th

gear.

GEAR SHIFTING

NOTE

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.

GEAR SHIFTING

CAUTION

When difficulty of shifting gears is experienced,

do not under any circumstance, attempt to force the

shift. The results of such abuse will be a damaged or

broken shifter mechanism, which if not avoided may

result in minor or moderate injury.

CAUTION

Shift gears to neutral before stopping engine.

Shifting mechanism can be damaged by shifting gears

while engine is stopped.

WARNING

Shifting to lower gears when motorcycle speed

is too high, can severely damage the transmission or

cause the rear wheel to lose traction resulting in

possible loss of vehicle control and loss of life or

serious injury.

Select a firm, flat surface

Hold handle bar straight

Lower center stand, and ensure that both the legs

of the stand are resting evenly on firm ground.

Apply pressure on the fulcrum lever on the center

stand and pull motorcycle backwards, gently.

PARKING

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 the motorcycle parts.

PARKING MOTORCYCLE ON CENTER STAND PARKING MOTORCYCLE ON SIDE STAND

Select a firm, flat surface

Lower Side Stand and gently tilt motorcycle to the

left till it rests firmly.

A side stand ON safety switch is fitted on the side

stand of the motorcycle. If the side stand is in

extended position, it will prevent the engine from

starting. Please ensure the side stand is retracted

fully before attempting to start engine.

TOOLS AND SPARES KIT

1. Tool Wallet 1

2. Tommy bar 1

3. Tubular spanner (21 x 24mm) 1

4. Screw driver 1

5. Double end spanners :

(10 × 13 mm) 2

(8 × 10 mm) 1

(14 × 15 mm) 1

(22 × 24) 1

(¼ “ X 5/16”) 1

6. Allen Keys :

(5 mm) 1

(3 mm) 1

(6 mm) 1

7. Tire Lever 2

As a fore thought, the following essential parts are

also provided with each motorcycle. Please ensure

that you collect these parts while taking delivery of

your motorcycle.

1. Speedo cable

2. Clutch cable

3. Pneumatic Tube for tire

RECOMMENDED LUBRICANTS

WARNING

Do NOT switch oil brands indiscriminately because some oil interacts chemically

when mixed. Use of inferior oils or non-detergent oils can damage the engine.

Engine oil 15 W 50 API SL Grade

Grade JASO MA, ESTER - Semi Synthetic oil

Capacity 2.75 Liters

Front Fork Fork oil

Capacity 200 m / leg.

Brake Fluid DOT 3 or DOT 4

Capacity 60 ml.

PRE OPERATIVE CHECKS

A careful check of the following must be carried out every time before riding and especially after long periods of

storage, to determine if additional maintenance is necessary.

1. Tires 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 directional 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 or loss of life.

The maintenance schedule detailed here will help you maintain your Royal Enfield motorcycle

meticulously and to get a long trouble free service. The schedule provided herein is based upon

average riding conditions and indicates the mileage at which regular inspections, adjustments,

replacements and lubrications must be carried out. The frequency of the maintenance must be

shortened depending upon the severity of the driving condition OR if the motorcycle is used in a

very dusty environment, severe climatic cold and hot conditions, bad roads, stagnant water 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 of regular maintenance at the suggested intervals may affect

the safe operation of your motorcycle causing the motorcycle to malfunction and stall

abruptly resulting in an accident and cause serious injury or loss of life.

PERIODICAL MAINTENANCE

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

Miles (x 1000) 0.3 2 3.75 6 7.5 9.5 11.25 13 15 17 18.75

12 Air filter element C C C C R C C C R C C

13 Inlet / Exhaust valve seating I I

14 Cylinder head D

15 Exhaust system D

16 Clutch free play Adjust every 1000 Kms or earlier as required

17 Rear brake pedal pivot L L L L L L L L L L L

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

19 Battery Electrolyte level I I I I I I I I I I I

20 Earth wire eyelet (behind battery carrier) I I

21 Rear Chain Adjust every 1000 Kms or earlier as required

Lubricate every 3000 Kms or earlier as required

22 Fork oil R R

Check level every 1000 Kms or earlier as required

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

DESCRIPTION SCHEDULE

No.

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

Applicable only for Motorcycles sold in the state of California.

PERIODICAL MAINTENANCE

NOTE

For maintenance after 18,750 miles (30,000 Kms), please repeat the same frequency

levels specified above, in consultation with a Royal Enfield Service Station.

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

Miles (x 1000) 0.3 2 3.75 6 7.5 9.5 11.25 13 15 17 18.75

23 Rear brake play Adjust every 1000 Kms or earlier as required

24 Rear brake cams L L L L L

25 Steering ball races L L

26 Spokes tightness I I I I I I

27 Wheel rim run out I I I I I

28 Tire wear I I I I I I I I I I

29 Hand levers pivot Lubricate every 1000 Kms or earlier as required

30 Evaporative Emission Equipment rubber hoses I I I I R I I I R I I

DESCRIPTION SCHEDULE

No.

MINOR MAINTENANCE TIPS

The following minor maintenance can be carried out

easily with simple tools. However, Incase, it is felt that

the adjustments are best done by an expert, we

recommend that the motorcycle be taken to a nearest

Authorized Royal Enfield service station.

Place motorcycle on its centre stand on a firm

surface.

Start the engine, warm up for a few minutes &

switch off

The oil level should be at the middle or slightly over

the middle level in the oil window in the RH Crank

case cover.

Top up with recommended oil if required

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

Max

Min

Caution

Do not fill oil over “MAX” mark. It may cause the engine

to smoke and result in loss of power. Do NOT use the

motorcycle if the oil is at the “MIN” mark. Doing so will

cause serious damage to the moving parts inside the

engine and result in an engine lock up.

MINOR MAINTENANCE TIPS

NOTE

Replace oil filter whenever oil is replaced.

Caution

Do not fill oil over MAX mark. It may cause the engine

to smoke and result in loss of power. Do NOT use the

motorcycle if the oil is at the MIN mark. Doing so will

cause serious damage to the moving parts inside the

engine and result in an engine lock up.

WARNING

Do NOT switch oil brands indiscriminately.

Some oils may react chemically when mixed. Use

of wrong grade, inferior OR non detergent oils can

damage the engine and lead to a potentially

hazardous situation which, if not avoided, could

result in severe damage to the engine parts and

ca us e the engine to lock up and stop the

motorcycle abruptly, which may result in an

accident and cause serious injury or loss of life.

ENGINE - OIL CHANGE

(Refer Periodical Maintenance Chart for frequency)

- Place motorcycle on its centre on a firm flat surface.

- Keep a clean tray below the engine.

- Start engine and warm sufficiently so as to help the

oil to drain out quickly.

- Remove the oil drain plug and the suction filter at the

bottom of the crankcase.

- Remove the oil filter on the RH Crankcase cover.

- Allow maximum oil to drain out by tilting the motorcycle

to both sides.

- Wash the drain plug and the suction filter thoroughly

and refit on the crankcase

- Soak a new filter element in oil and refit on the RH

Crankcase cover.

- Fill recommended oil till the oil level is between the

MAX and MIN marks in the oil level window in the RH

Crank case cover.

- Start the engine, warm up for a few minutes & switch

off

- Check the oil level after two minutes to see if the oil

level is at the middle or slightly over the middle level

in the oil window.

- Top up with recommended oil if required

BRAKE FLUID

Check if the brake fluid is above ‘min’ level. To

top up, remove cover and diaphragm and top

up with either DOT 3 or DOT 4 as specified.

Cl eaning and adj usting gap (Refer

Periodi cal Maintenanc e Char t for

frequency)

Remove the spark plug cap from the spark plug

Remove the spark plug from the cylinder head

using a suitable plug spanner.

Clean the insulator tip and electrodes of the plug

carefully in a spark plug cleaning and testing

equipment.

Set the gap between 0.7 to 0.8 mm.

Refit the spark plug on the cylinder head and fit

the spark plug cap.

MINOR MAINTENANCE TIPS

Caution

Brake fluid is high corrosive and can cause

damage to painted parts. Please ensure that

brake fluid does not spill on any part of the

motorcycle. In the event if a spill, please clean

the area immediately with a soft cloth

(preferably a wet cloth) to avoid damage.

SPARK PLUG

INSPECTION OF TIRES AND WHEELS

Use only standard tires & tubes inflated to correct

pressure. Using a motorcycle with improperly inflated

tires can cause instability while riding or cornering.

MINOR MAINTENANCE TIPS

WARNING

Tires, rims and air valves must be correctly

matched to wheel rims. Mismatching tires, tubes,

rims and air valves may result in damage to the tire

bead during mounting which will cause tire slippage

on the rim and cause tire failure. Please replace tires

if bald spots or swelling is noticed. Replace tires

which are worn out, punctured or damaged. Small

punctures in the tread area may be repaired from

within the tire. Do not ride the motorcycle over 40

MPH (60 Kmph) for the first 24 hours and over 55

MPH (90 Kmph) thereafter with a repaired tire. In

emergency situations, please ride slowly with least

possible load until the tire is permanently repaired

or replaced. Failure to heed to this warning could

result in serious injury or loss of life.

Please inspect and ensure tires are seated evenly &

properly in the rims. Check proper seating of the tire

beading on the rim Inspect the tires periodically for tread

wear, cracks and cuts. Maintain the recommended tire

pressures as it is very important for riding stability. Pay

strict attention to loose and / or broken spokes Check

spokes for correct tightness in the rims Whenever a new

tire is installed, ensure rim and spokes do not get

damaged on account of using wrong levers. Ensure the

front and rear wheels are correctly aligned. and free

movement of steering system.

Check and remove stone, splinters, nails or other

particles embedded in the tire treads.

Inspect the tires thread condition periodically and

replace worn out tires with approved make only.

Failure to do so can lead to improper balance, poor

stability, poor handling, and abnormal tread wear.

Minimum tread depth :

Front tire : 1mm Rear tire : 2 mm

Tire pressure

Front

Solo 1.27 kg/cm2 (18 PSI)

With Pillion 1.41 kg/cm2 (20 PSI)

Rear

Solo 2.00 kg/cm2 (28 PSI)

With Pillion 2.11 kg/cm2 (30 PSI)

Caution

Do not depress the front brake lever when wheel is

removed as this will result in the brake pads coming

too far out of the brake caliper.

Place a 4 mm thick wooden piece or cardboard

sheet between the brake pads to avoid pads

activation in the event the front brake lever is

accidently depressed.

FRONT WHEEL REASSEMBLY

Remove the wooden piece / card board sheet

placed between the brake pads

Locate the speedo drive bush in position and place

speedo drive over it.

Insert the wheel along with speedo drive and RH

spacer between the fork ends ensuring the brake

disc is located between the brake pads.

MINOR MAINTENANCE TIPS

Insert and tap the front wheel axle gently inside.

Refit the washer and tighten the nut firmly.

NOTE

Ensure that the speedo drive is correctly located

such that the cable can be connected without

difficulty.

Tighten the pinch bolt on the RH fork guide.

Rotate the wheel and check for smooth rotation.

Connect the speedo cable to speedo drive and

check for proper working of speedo meter.

Depress brake lever 2 or 3 times to check front

brake efficiency.

MINOR MAINTENANCE TIPS

REAR WHEEL REMOVAL

Place motorcycle 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.

Loosen lock nut.

Screw in or out the adjuster for setting the required

play.

Tighten lock nut.

Refit the clutch cable boot.

ADJUSTMENTS

Clutch cable (play 2-3 mm)

a. Clutch Play Adjustment

MINOR MAINTENANCE TIPS

Drive Chain tension (play 25 - 30 mm)

Remove rear wheel split pin.

Loosen castle nut, spindle nut, anchor nut and

brake rod nut.

Turn the RH adjuster cam as appropriately, till 25

to 30 mm slackness is achieved on the top run of

the chain.

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 notches on the cam are

resting on the pin in the swing arm on both sides.

Apply brake and tighten all nuts.

MINOR MAINTENANCE TIPS

REAR BRAKE PEDAL HEIGHT

Loosen the lock nut

Turn in or out the pedal stop pin till the brake pedal

and front footrest are in the same height

Tighten the lock nut

Check for free rotation of rear wheel.

REAR BRAKE

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.

MINOR MAINTENANCE TIPS

WARNING

Please ensure brakes are adjusted to their

maximum efficiency. Improperly adjusted brakes

can result in an accident causing serious injury or

loss of life

Please ensure adequate caution while applying

brakes. Sudden application of brakes can lock the

wheel and cause possible loss of control of the

motorcycle which can result in an accident causing

serious injury or loss of life.

WARNING

Brake shoes must be inspected for wear

every 2500 miles (4000 Kms). If you ride under

adverse conditions, (steep hills, heavy traffic, etc.)

a more frequent inspection at 1000 miles (1600

Kms) or less, is required.

CHAIN LOCK FITMENT

The chain link lock should be fitted such that the closed

end of the chain lock is towards the normal direction

of chain rotation

WARNING

Fitting the chain lock in the wrong direction

can lead to it falling off while riding and the chain

can disengage from the sprockets. This will lead

to a potentially hazardous situation which can

result in an accident causing serious injury or loss

of life.

MINOR MAINTENANCE TIPS

REAR SHOCK ABSORBERS WARNING

Regularly inspect shock absorbers and

front forks for leaks. Replace if leaking or defective

as they can adversely affect the stability and riding

of the motorcycle.

Riding the motorcycle with the notches adjusted

in different positions can cause loss of control and

may result in an accident causing serious injury

or loss of life.

NOTE

Ensure no fouling of any accessories with rear

shock absorber. Check for sufficient gap between

the shock absorber and any accessories/cargo

when the rear end of the motorcycle is fully loaded

and the shock absorbers are fully compressed.

The rear shock absorbers have a five step adjuster

to increase or decrease the spring tension.

Increase the spring tension for high load operation

and reduce the spring tension for low load

operation.

Turn the adjuster clockwise to increase the spring

tension and vice versa to reduce the spring tension.

Please ensure the spring tension is adjusted evenly

on both shock absorbers.

MINOR MAINTENANCE TIPS

REM OV AL OF BAT TE RY FRO M THE

MOTORCYCLE

Unlock and remove the battery cover.

Remove the two rubber straps holding the battery.

NOTE

For checking the battery voltage and electrolyte

specific gravity, contact authorised battery service

centre.

WARNING

Always disconnect the negative (-) battery cable

first and then the positive (+) cable while removing the

battery connections. If the positive (+ve) battery cable

should contact terminal with the negative (-) cable

installed, the resulting sparks may cause a battery

explosion which could result in serious injury or loss

of life.

BATTERY MAINTENANCE

The motorcycle is provided with 12V - 14 AH battery.

The battery must be periodically checked for

Cleanliness and corrosion free terminals.

Electrolyte level

if electrolyte level is low, top up with distilled

water.

Pull the battery out slightly and disconnect both

the terminal wires (negative and positive)

Take out the battery.

MINOR MAINTENANCE TIPS

Caution

Do not use battery with low electrolyte level as the

battery internals will get damaged.

Do not overfill the battery electrolyte level as it will

spill out through the overflow pipe and cause

corrosion to motorcycle parts.

Use only distilled water meant for use in batteries

to avoid damage to battery.

WARNING

Battery terminals and internals contain lead

and lead components, known to cause cancer and

birth defects or other reproductive harm. Wash

hands after handling the Electrolyte, which is a

sulphuric acid solution. Electrolyte is highly

corrosive and can cause severe chemical burns,

Avoid contact with skin eyes and clothing. Always

wear approved protective face shield, rubberized

gloves, and protective clothing when working with

batteries or electrolyte solution. KEEP BATTERIES

AND ACID OUT OF REACH OF CHILDREN.

RE A SS E M B LY OF BA T TE RY ON

MOTORCYCLE

Position the battery in the battery carrier such that

the terminals are facing inside.

Connect the positive terminal (Red wire) first.

Connect the negative terminal (Black wire) last.

Smear the terminals with petroleum jelly. (Do not

use grease).

Locate the battery in the battery carrier and secure

with the rubber straps

Locate the battery cover in place and lock the

cover.

MINOR MAINTENANCE TIPS

CHANGING ELECTRICAL COMPONENTS

Head Lamp

Th e hea dlamp is se ale d bea m typ e. Wh e n

replacement is required use only the specified sealed

beam unit available from your dealer. Using a wrong

sealed beam may harm the electrical system in the

motorcycle.

Removing the Headlamp sealed beam

Loosen the rim holding screws - 1 on top and 2 at the

sides and take out the head lamp assembly.

Disconnect the electrical connections, remove the

rubber grommet and the sealed beam.

Reassembling the Headlamp sealed beam

Refix the new sealed beam in the headlamp rim.

Fit the rubber grommet and connect the electrical

connections

Position head lamp on the head lamp casing and

tighten the mounting screws.

Tail Lamp Bulb

Remove the two nuts holding the rear plate.

Remove the three screws holding the tail lamp to

the bracket.

Twist the bulb holder anti clockwise and remove.

Remove the old bulb and replace with a new bulb.

MINOR MAINTENANCE TIPS

Refit the bulb holder and turn clockwise to lock the

bulb holder.

Refit the tail lamp on the bracket and rear plate.

Trafficator bulb

Remove the screws & the cover.

Depress bulb, Turn anti clockwise and take out the

bulb.

Position the new bulb inside the holder, ensuring

that the pins in the bulb, match with the slots in the

holder.

Press the bulb and turn clockwise to lock the bulb

in the holder.

Refit the trafficator cover and the screws.

Caution

Do Not touch the bulb with your fingers. Finger prints

will etch the glass and decrease the light intensity.

Always hold the bulb with a tissue paper or clean dry

cloth during handling.

MINOR MAINTENANCE TIPS

FUSE

Open the LH tool box

The fuse holder is located inside with 3 fuses of

20 Amps each - One for Charging circuit, One for

Other electrical loads and one for the EFI System.

Replace the required fuse with the spare fuse

available in the fuse carrier.

Please ensure to replace a spare fuse in the holder

at the earliest opportunity.

PRECAUTIONS

Wash motorcycle when the engine is cold.

Cover the silencer 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 jet of water to clean the entire

motorcycle.

Never spray water with great force on head lamp,

speedometer, flasher lights, front and rear wheel

hubs, electrical connections and wires, control

cables, Throttle body, sparkplug, battery, etc.

WASHING PROCEDURE

Use Luke warm water and mild detergent on the

painted components to remove dirt, etc.

Rinse motorcycle thoroughly with plain water to

remove the detergent and wipe motorcycle dry.

If possible, use compressed air and blow off water

particles from the obscure areas of the motorcycle,

electrical connections, etc.

AFTER WASHING

Ensure, the motorcycle is thoroughly dry by wiping

with a clean soft absorbent cloth or chamois

leather.

Remove all plastic bags and adhesive tapes.

Lubricate control cables, pivot and rear chain with

lube oil

Polish the painted and plated surfaces using

polishing wax.

WASHING PROCEDURE

Start engine and allow to run at idling speed for a

few minutes to warm up engine.

Drive the motorcycle slowly, applying both brakes

intermittently to dry up the brake shoes.

Test brakes for full efficiency.

WARNING

Observe warnings and cautions given on

labels of cleaning compounds.

When washing your motorcycle, be careful not to

get the brakes, engine, mufflers or air cleaner etc.,

too wet. Wet brake shoe and / or brake drum can

affect braking. Ensure brakes and the motorcycle

is operating properly before riding in traffic.

Incase your Motorcycle is not going to be used for a

month or more, we advice the following precautions

to the taken.

Carryout required repair / adjustments on the

motorcycle.

Wash the motorcycle thoroughly and lubricate as

per the maintenance chart.

Start the engine, warm up for a few minutes and

switch off.

Drain out the fuel completely from the fuel tank and

fuel lines.

Remove spark plug. Pour in about 50 ml of clean

engine oil through spark plug hole. Close the hole

and crank engine several times and refit sparkplug.

Clean rear chain thoroughly and apply a thin film

of lube oil.

Remove battery from the motorcycle. 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, dry and well ventilated

place.

Do not place the battery in direct sun light, near

open flame or where temperature is above 40

or below 0oC

Cover the silencer with plastic bags to prevent

moisture entry. Set the motorcycle on its center

stand.

Apply anti rust solutions on all plated parts. Take

care not to apply this solution on rubber or painted

parts.

Store motorcycle in a clean covered area free - of

moisture and keep it covered to prevent dust

settling on it.

STORAGE PRECAUTION

PREPARING THE MOTORCYCLE FOR REUSE

Remove the anti rust solution from all plated parts

and clean the motorcycle well.

Inflate the tires to the correct tire 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 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 a few times

to lubricate cylinder walls and piston. Clean spark

plug and refit

Switch on ignition switch.

Start motorcycle and warm up engine for a few

minutes before riding the motorcycle.

NOTE

Do not raise the engine rpm the moment it is

started, but allow the engine to run at idling speed.

Caution

Proper long-term storage is important for the safe,

trouble-free operation of your Royal Enfie ld

motorcycle.

STORAGE PRECAUTION

SAFETY RIDING TIPS

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 of

stickers at the front and rear.

NOTE

A light colored shirt enables greater visibility to

other road users especially during nights.

Caution

Loose clothing may get caught on moving parts of

your motorcycle.

SITTING POSTURE:

Correct sitting posture is a prerequisite for stable and

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 view

mirrors, without turning the head.

BRAKING

Apply front and rear brakes gently and

simultaneously for maximum braking efficiency.

WARNING

Applying any one of the brakes suddenly

may cause the motorcycle to skid. The hydraulic

disc brake fitted on your motorcycle requires very

less effort. High effort or sudden application may

lock the wheel. Please use utmost caution while

applying the brakes.

While riding on wet or bad road conditions use

brakes cautiously.

Avoid excessive banking, otherwise footrest may

touch the ground and cause instability.

Checks prior to the commencement of

long journey

Service the motorcycle through a Royal Enfield

authorised service centre as per period ical

maintenance chart.

Ensure there is sufficient quantity of petrol in the

fuel tank.

Correct tire pressure.

Correct oil levels in Engine, brake master cylinder.

Good battery condition and electrolyte level.

Proper chain tension and correctly adjusted rear

brakes.

Check for proper functioning of all lights & horn

etc.,

Checks after every 930 miles (1500 kms)

of run

Tightness of all fasteners.

Tire treads condition and wear of tires.

Battery condition and electrolyte level.

Correct level of oil in engine, brake fluid.

Working of all lights and horn.

Proper chain tension.

Items to be carried

Tool kit

First aid kit.

Bulbs for headlight, trafficator light, rear tail lamp

and fuse (20 Amps).

Accelerator, clutch, and Bi starter cables.

Rear chain link lock assembly.

Spare tu be , tire pu nct ure repair kit - co ld

vulcanizing type.

Foot operated air pump.

Insulation tape.

Spark plug, spark plug cap, fuel hose.

LONG TRIP PRECAUTIONS

WIRING DIAGRAM

WIRING DIAGRA M

WIRING DIAGRAM

TROUBLE SHOOTING

WARNING

The trouble shooting section of this Owner’s Manual is intended solely as a guide to diagnosing

problems. Carefully read the appropriate sections of this manual before performing any work. Repair and

maintenance operations not listed in this Owner’s Manual should be performed by your Royal Enfield

Dealer only. Improper repair and/or maintenance could result in the motorcycle not functioning properly,

serious injury or loss of life.

Causes Remedies

I. Engine fails to start

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

2) Side stand not retrieved .................................................. Retrieve side stand.

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

4) Spark plug cap / lead not connected .............................. Fix cap / lead firmly

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

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

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

* Contact Royal Enfield Dealer

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.

III. Engine starts, but runs irregularly & stops

1) Faulty fuel supply .......................................................... * Remove fuel pump & clean.

(fuel pump, filter blocked)

Causes Remedies

TROUBLE SHOOTING

* Contact Royal Enfield Dealer

IV. Poor pickup

1) Accelerator cable free play excessive .............................. Adjust cable free play

2) Faulty fuel supply ............................................................. * Remove fuel pump & clean.

Fuel pump / filter blocked

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

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 tires .......................................................... * Inflate to correct pressure

V. White/blue smoke

Oil level in tank above the Top line in the ...................... * Check and drain excess oil

oil level window

Causes Remedies

TROUBLE SHOOTING

* Contact Royal Enfield Dealer

VIII. 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

IX. Motorcycle wobbles

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

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

3) Tires not fitted correctly ................................................... * Refit tires correctly

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

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

Causes Remedies

TROUBLE SHOOTING

* Contact Royal Enfield Dealer

Product specificaties

Merk:	Royal Enfield
Categorie:	Motor
Model:	Bullet 500 EFI (2011)

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