Bullet 500 - Royal Enfield

Congratulations on becoming the proud owner of a legendary Royal Enfield motorcycle. The new Bullet 500 is a motorcycle with the timeless handcrafted design of the legendary Bullet, now fitted with a solid 500cc Unit Contruction Engine with twin-spark ignition for better combustion, superior power delivery and improved fuel economy. Do read this manual thoroughly before you begin riding to ensure that you operate your motorcycle the right way, are aware of the terms and conditions of warranty, and know how to maintain it properly. We urge you to avail o f the fo ur fr ee s er vices we o ffer, at the r ight tim e, at any of o ur Autho ri sed Dealer / Service Point to keep your motorcycle in peak condition. Please log on to w w w.r o y a l en f i e l d .c o m to kno w m or e abo ut the his to ry o f the wo rl d’s oldest motorcycle brand, our other products, and for exciting news of riding tours and events organised for Royal Enfield motorcycle owners. Welcome to motorcycling the Royal Enfield way. Ride safe and enjoy the trip!

IMPORTANT NOTICE Keep this manual in a convenient place for easy reference.

Beca us e o f co n tino us i m pro vem e nts i n t he pro duct and changes that may occur in the manufacturing process, subsequent to printing of this m anual , i t i s po ssible so me instr uctio ns, illustrations, pictures or designs found within this m anual m ay dif fer fro m tho se fo und on the vehicle.

If any information is not understood in the manual contact your Authorised Dealer / Service Point for assistance. If the motorcycle is being used by any friend, relatives, or others it is responsibility of the owner to make certain that the owner’s manual is read and fully understood prior to usage and has been instructed on it’s safe and proper use.

However the technical information found within thi s m a nual was co r r ect at the ti me i t was approved for publication.

The motorcycle is designed for normal on road use only. Operation in off-road usage in some areas may be illegal and could be dangerous.

Ro yal Enfi eld r es er ves the r ig ht t o m a ke production changes at any time without prior notice and without incurring any obligation to m ak e s am e o r s i m ilar chan ges to vehi cles previously built or sold.

Obey local law and regulations.

In the event of motorcycle being resold, it is the responsibility of the owner of the motorcycle to hand over the manual along with the motorcycle and it’s documents.

“© Copyright 2014 Eicher Limited, Royal Enfield Unit. All Rights Reserved. No part of this manual shall be copied, distributed or otherwise dealt without the express permission in writing of Eicher Motor Limited, Royal Enfield Unit.” Part No. 584639/A / Qty.1000 / Apr. ‘14 2

IMPORTANT NOTICE SAFETY DEFINITIONS

However i f you have any queries, cl ar ifi cation,

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

suggestions/feedback, please write to us or e-mail at “[email protected]”.

WARNING War ni ng i ndicates a potenti all y hazardo us situation, which if not avoided, could result in serious injury.

CAUTION Caution indicated a protentially hazardous situation, which if not avoided, may result in property damage, in minor or moderate injury.

NOTE

SERVICE HEAD QUARTERS

Indicates important and useful messages for clearer understanding.

Thiruvottiyur High Road, Thiruvottiyur,

Royal Enfield, A Unit of Eicher Motors Limited, Chennai - 600 019. Phone : 044 - 4223 0400, Fax : 044 - 4201 1719

All Images shown are for reference to explain and need not to be exactly the same on the model you own.

E-mail : [email protected] Website : www.royalenfield.com 3

CONTENTS PERSONAL & VEHICLE INFORMATION ......................... 7

OPERATION OF CONTROLS .............................................. 26

FREE SERVICE RECORD ..................................................... 8

- Ignition Switch ......................................................... 26

SAFE OPERATING RULES .................................................. 9

- Steering lock ............................................................. 26

RULES OF THE ROAD ......................................................... 15

- Fuel tank cap ............................................................ 27

TECHNICAL SPECIFICATIONS ......................................... 17

- Side Box ...................................................................... 27

- Engine ........................................................................ 17

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

- Ignition System ........................................................ 18

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

- Transmission ............................................................ 18

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

- Electricals ................................................................. 19

- Engine Kill Switch .................................................... 29

- Chassis ....................................................................... 20

- Ho rn ............................................................................. 29

- Dimensions ............................................................... 21

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

- Weights ...................................................................... 21

- Engine Start Switch ................................................. 30

VEHICLE IDENTIFICATION NUMBER ............................. 22

- Battery Box ................................................................ 30

KEY PARTS LOCATION ....................................................... 23

- Fuel Tap ...................................................................... 30

- Top View .................................................................... 23

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

- Right Side View ........................................................ 24

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

- Left Side View ........................................................... 25

STA RT ING ............................................................................. 33 4

CONTENTS GEAR SHIFTING .................................................................. 35

- Rear wheel removal ............................................. 49

PA RKING ............................................................................... 36

- Rear wheel assembly ........................................... 50

- Center Stand ............................................................ 36

- Adjustment - Clutch ................................................ 51

- Side Stand ................................................................. 36

-

Drive Chain tension ......................................... 51

TOOLS AND FIRST AID KIT ............................................. 37

-

Checking Rear Brake Pedal height ........... 52

RECOMMENDED LUBRICANTS ....................................... 38

-

Rear Brake Pedal height Adjustment ....... 53

PERIODICAL MAINTENANCE ......................................... 39

-

Chain Lock Fitment .......................................... 53

MINOR MAINTENANCE TIPS ......................................... 43

-

Adjustment of Gas Filled Shockabsorber .... 54

- Control Cables, Handle bar lever, Pivots, Center / Side Stand Pivots ....................... 43

- Removal of Battery on Vehicle ........................... 55

- Engine Oil Level Inspection ................................. 43

- Assembly of Battery on Vehicle ......................... 56

- Engine Oil Change ................................................. 44

- Changing Electrical Components .................... 57

- Battery Maintenance ............................................ 55

- Spark Plug ................................................................. 45

-

Head Lamp bulb replacement .................. 57

- Brake fluid ................................................................. 46

-

Tail Lamp bulb replacement ...................... 59

- Inspection of tyres and wheels ........................... 46

-

Trafficator bulb replacement .................... 59

- Tyre pressure ............................................................ 47

-

Fuse ....................................................................... 60

- Front Wheel removal .............................................. 47

-

Blade Fuse usage List ..................................... 60

- Air Filter element cleaning / replacement ... 61

- Front Wheel assembly ............................................ 48 5

CONTENTS WASHING PROCEDURE .................................................... 62

- Excessive fuel consumption ................................ 72

- Precautions .............................................................. 62

- Ignition knock .......................................................... 73

- After Washing .......................................................... 62

- Brakes poor .............................................................. 73

STORAGE PRECAUT ION .................................................. 63

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

- Preparing the motorcycle for reuse .............. 64

- Electricals .................................................................. 74

LONG TRIP PRECAUTIONS ............................................. 65

- Electric Start .............................................................. 76

- Checks prior to the commencement .............. 65

WARRANTY TERMS & CONDITIONS ............................ 77

- Checks after every 1500 kms ............................. 65

EMI SSION WARRA NTY ...................................................... 79

- Items to be carried ............................................... 65

A LL INDIA ROA D SIGNS ....................................83

CARING FOR MILEAGE ................................................... 66

FREE SERVICE COUPONS .................................................. 84

COMPLETE WIRING DIAGRAM - BULLET 500 ........... 68

PAID SERVICE / MAINTENANCE RECORD ................... 93

TROUBLE SHOOTI NG ....................................................... 69

LOG BOOK ............................................................... 101

- Engine fails to start ............................................... 69

NOT ES ...............................................................106

- Engine misfiring ..................................................... 70

A NN EXUR ES

- Engine starts, but runs irregularly & stops ......... 71

- Vehicle Installation Form

- Poor pickup .............................................................. 71

- Pre-Delivery Inspection Report (PDI)

- White / blue smoke ................................................ 72

- Bike Installation Confirmation By Customer

- Engine over heating ............................................. 72

- Form 22 6

PERSONAL & VEHICLE INFORMATION Name Door No./Street Locality City Contact Nos.

State Res:

Off:

Pin

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

Vehicle Installation Form (VIF) No. 7

FREE SERVICE RECORD It is our endeavour to provide excellent service to your Bullet 500 at all times. Towards this we provide 4 free services at specific Intervals. Please avail these services at the specified time, in any of the Royal Enfield Authorised Dealer / Service Point nearest to you and as a token of satisfactory services, kindly return the free service coupon duly filled in and signed, to the service outlet. Availing the free services in the specified time is a prerequisite for warranty consideration. The cost of fuel, oil, grease etc. used for all free services are chargeable to the customer. 1 st Service

2 nd Service

3 rd Service

4 th Service

Dealer / ASP Rubber Stamp




Date of Service Kms Covered Servicing Dealer’s / ASP Name, Address

NOTE Please ensure that the free service details are recorded in this sheet immediately after the service is carried out. 8

SAFE OPERATING RULES Before operating your new motorcycle, it is your

Use only genuine Royal Enfield spare parts and

responsibility to carefully read and follow the

approved accessories. Use of other manufacturer’s

operating and maintenance instructions detailed

performance parts may affect the performance of

in thi s m a nual f or you r o w n s a fety, yo ur

your motorcycle and render the motorcycle void of

motorcycle and that of others.

warranty. See your Royal Enfield dealer for details.

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

Whenever refuelling your mo torcycle, please

rider for your own safety and for other road users.

exercise utmost caution and carefully observe the

Before starting the motorcycle, check for proper

following rules :

operation of brakes, clutch, gear shifter, handle

DO NOT smoke and please ensure that there

bar controls, tyre pressures, fuel and oil levels.

are no open fla m es or s park s ne ar t he motorcycle, when refuelling OR servicing the

WARNING

fuel system.

Royal Enfield cautions you against the use of certain nonstandard parts such as aftermarket and

Switch OFF mobile phones and other hand

custom made extended front forks or suspensions,

held electronic devices / gadgets.

whi ch m ay a dver sely aff ect per f o rm a nce and

Open the fuel filler cap slowly.

handling. Removing or altering original parts may adversely affect performance and could result in an

Refuel in a well ventilated area with the engine

accident causing serious injury.

turned off. 9

SAFE OPERATING RULES DO NOT fill the tank to its brim. Please fill fuel

A new motorcycle must be operated according to the special break-in-procedure. See BREAK-IN-THE FIRST 500KM section.

only till the bottom of the filler neck insert, so as to leave air space in the fuel tank to allow for fuel expansion (for Spec. Ref. Page No. 20).

Operate motorcycle only at moderate speeds and out of traffic until you have become thoroughly fa m il i ar w i th i ts o per ati o n an d ha ndl i ng characteristics under all conditions.

WARNING Pe tr ol is extre m el y fl am m able an d h i gh ly

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.

explosive. Use care when handling Petrol. Always stop the engine when refuelling or servicing the fuel system. Do not smoke or allow open flames or sparks near Petrol. Do not store motorcycle with

Petrol in

the tank, within the home or garage where open flames, pilot lights, sparks or electric motors are present. Inadequate safety precautions could cause

NOTE

an explosion or fire which could result in damage to

If you are an inexperienced rider we recommend that you obtain formal training on correct motorcycle riding techniques and become thoroughly familiar with the operation of your particular motorcycle. New ri ders s ho uld gai n ex p er i ence und er v ar io us conditions while driving at moderate speeds.

property, serious injury.

10

SAFE OPERATING RULES WARNING

Ope rat e yo ur m otor cycl e de fens ivel y. Remember, a motorcycle does no t af ford the same protection as an automobile in an accident. One o f the mo st com mon accident situati ons occurs when the driver of the other vehicle fails to see or recognize a motorcycle and turns into the oncoming motorcyclist.

Avoid overspeeding and never travel over the speed limit. Excessive speed may cause loss of control and could r esult in an accident caus ing serious injury. DO NOT exceed >110 km/h solo riding. DO NOT exceed >90 Km/h when carrying a pillion or cargo.

Wear an appro ved helmet, clothing, and foot gear suited for riding a motorcycle. Bright OR light colors are best for greater visibility in traffic, specially at night. Avoid loose, flowing garments and scarves.

Pay strict attention to road surfaces and wind conditions . Any two wheeler vehicle may be subject to the following upsetting forces : Wind blasts from passing trucks.

Whe n ca r r yi ng a pil lio n r id er, it i s yo ur responsibility to instruct them on proper riding procedures.

Rough uneven road surfaces. Slippery road surfaces. These forces may affect the handling characteristics of your motorcycle. If this happens, reduce speed and gui de the m o to rcycle wi th a r el ax ed gri p to a controlled condition. Do not brake abruptly or force the handlebar.

DO NO T allo w o ther in dividual s , 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. 11


In emergency situations, if a temporary repair is

M ai n tai n th e reco m m ended t yre pr ess u r e.

made ride slowly with as light a load as possible until

Ens ur e the f ro nt and r ear wheel s ar e co rr ectly

the tyre is permanently repaired or replaced.

aligned and the tyres are seated evenly & properly in the rims. Check for correct tightness of the spokes

Failure to heed this warning could result in serious

in the r im s. Inspect your tyres peri odically and

injury.

replace tyres with approved tyres only. Failure to do so can lead to improper balance, abnormal tread

Safe motorcycle operation requires alert mental

wear, poor handling and could resul t in serious

judgement combined with a defensive driving

injury.

attitude. DO NOT allow fatigue, alcohol or drugs to endanger your safety or that of others.

WARNING

Maintain your motorcycle in proper operating

Royal Enfield recommends replacement of any

condition as per Periodical Maintenance Chart

tube / tyre punctured or damaged. In some cases

(R ef Page No .4 0 ). Par t icu l ar l y i m po rt ant to

small punctures in the tread area may be repaired from within the demounted tyre by your Royal Enfield

m ot or cy cl e stab ili t y is pro per tyre i nf lati o n

dealer. Speed should not exceed 60 km/h for the first

pressure, tread condition. Pay strict attention to

24 hours after repair and the repaired tyre should

loose and / or broken spokes, free movement of steering system.

Never be used over 90 km/h (applicable tube less tyre) 12


WARNING

Avoid any contact with the exhaust system. Wear clothing that will completely cover the legs while riding. The exhaust system gets very hot when the engine is running and remains too hot, even after the engine is turned off (due to catalic converter). Failure to wear proper or protective clothing could result in serious injury.

DO NOT operate motorcycle with a loose, worn or damaged steering system, including the front and rear sus pensio n 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.

WARNING

WARNING

Regularly inspect rear shock absorbers and front forks and look for leaks. Replace worn parts. Worn parts can adversely affect stability and handling.

Ex haus t ga s es cont ain s po i so n o us car b on mono xide (CO.) and chemi cals , known to cause serious health hazards.

WARNING

WARNING

For your personal welfare, all the listed service and m aintenance recom m endatio ns sho ul d be per fo rm ed. Lack of regular maintenance at the suggested intervals may affect the safe operation of your motorcycle, which could result in serious injury.

Motor cycle batteri es contain lead and lead components, acids and chemicals known to cause serious health hazards. Exercise extreme caution while handling a battery. Wash hands thoroughly whenever a battery is handled. 13


on the frame Down tube. (GVWR is the sum of the wei ght of the m otor cycle, acces so ries, and the maximum weight of the rider, passenger and cargo that may be safely carried.) Exceeding GVWR may lead to instability of the motorcycle, which could cause an accident and result in serious injury.

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.

WARNING

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 .

Use only genuine Royal Enfield replacement fasteners tightened to the proper torque. We caution you against the use of certain non standard parts such as aftermarket and cus tom 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.

WARNING DO NOT pull a trailer behi nd a mo to rcycle. To w ing a tr ai le r ma y ca use redu ced brak i ng efficiency, tyre overloading and unstable handling. Towing a trailer may cause loss of control of the m otorcycl e in the front, leading to an acci dent resulting in serious injury.

WARNING DO NOT exceed the Gross Vehicle Weight Rating of your motorcycle. The Gross Vehicle Weight Rating (GVWR) is shown on the information plate, located 14

RULES OF THE ROAD Be sure front & rear number plates is installed in the position specified by law and is clearly visible at all times.

may cause loss of control of vehicle, which could result in death or serious injury.

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 :

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

Dry Icy

Always sound your horn, actuate your turn signals, and exe rcis e CA UTI ON w hen pass ing oth er 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.

Oily Wet

Watch for loose debris, such as leaves, slippery substances or loose gravel that can hamper the stability of your vehicle.

At street intersection give the right-of-way to the vehicle on your left or right. DO NOT presume you have the right-of-way.

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.

Always signal when preparing to stop, turn or pass. Whi le tur ning either r igh t o r l eft, watch fo r pedestrians, animals as well as vehicles. 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.

WARNING Avoid excessive speed and never travel at a speed faster than the speed limit. Excessive speed 15

RULES OF THE ROAD When intending to turn, signal at least 100 feet (30.5 meters) before reaching the turning. Be close to the center line (unles s l ocal r ul es requir e otherwise), slow down and then turn carefully. Never jump a traffic light. When a change is imminent from GO to STOP (or vice versa) at intersections, slow down and wait for the light to change to green. Never run through a yellow or red traffic light.

SIDE VIEW MIRRORS

Red Yellow

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

Green

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.

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

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

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.

Pr o tec t yo ur m o to r cycl e ag ains t th eft. A ft er parking your motorcycle, remove Ignition key from switch and lock the steering head. 16

TECHNICAL SPECIFICATIONS ENGINE Engine ............................................................

Single Cylinder, 4 Stroke, Twinspark, Aircooled

Capacity ........................................................

499 cc (Displacement)

Bore ................................................................

84 mm

Stroke .............................................................

90 mm

Compression ratio ......................................

8.5 : 1

Max. Power @ RPM .....................................

26.1 BHP @ 5100 rpm

Max. Torque @ RPM ...................................

40.9 Nm @ 3800 rpm

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

Corrugated Paper Element

Fuel Supply ...................................................

Carburetor with Throttle Position Sensor (TPS)

Engine Start ..................................................

Electric / Kick

Engine Oil Capacity ...................................

2.75 Litres.

Lubrication ...................................................

Wet Sump, Forced Lubrication

Engine Oil Grade ........................................

Royal Enfield 15W50 API SL Grade Engine Oil (JASO MA)

Cooling system ............................................

Natural Air Flow

Carburetor ...................................................

UCD 33 17

TECHNICAL SPECIFICATIONS IGNITION SYSTEM Ignition system ...........................................

TCI Unit, Multi Curve (Variable Ignition Timing)

Spark plug ...................................................

WQR8DC (Bosch Super) M14 & UR6DC (Bosch Super) M10

Spark plug Electrode gap ...................... .................................................................

WQR8DC 0.80 to 0.90 mm UR6DC 0.70 to 0.80 mm

TRANSMISSION Clutch ............................................................

Wet Multiplate (7 Plates Clutch)

Primary drive ..............................................

Duplex Chain

Primary Drive Ratio ...................................

2.15 : 1

Gear box .......................................................

5 Speed Constant Mesh

Gear shift pattern ......................................

1-N-2-3-4-5

Gear Ratios ..................................................

1st-3.06:1

Secondary Drive (F.D. Sprocket) ............

18 Teeth

Final Ratio ....................................................

2. 11 : 1

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

102 links

2nd-2.01:1

18

3rd-1.52:1

4th-1.21:1

5th-1:1

TECHNICAL SPECIFICATIONS ELECTRICALS Generation ...................................................

Alternator

System ............................................................

12V DC

Battery ...........................................................

12V - 14 AH

Head lamp ...................................................

12V, 60/55 W, Halogen

Position lamp ..............................................

12V, 4W

Brake / Tail lamp .......................................

12V, 21/5 W

Turn signal ...................................................

12V, 10W - 4 nos.

Pilot lamp .....................................................

12V, 2 W - 2 nos.

Speedometer lamp ...................................

12V, 3.4 W - 1 no.

Turn signal / High beam indicator ......

12V, 1.7 W - 2 nos.

Neutral Indicator .......................................

12V, 1.7 W - 1 no.

Horn (Dual) ..................................................

12V, 2.5 Amp (Max.) X2

Starter Motor ...............................................

12V, 0.9 KW 19

WARNING Using bulbs / other electrical gadgets other than specified rating may lead to over loading / erratic behaviour / prematur e fai lur e of electrical system. Modifications on the bike which are not approved by Royal Enfield may not only disqualify for warranty, but also affects performance of the bike.

TECHNICAL SPECIFICATIONS CHASSIS Frame .............................................................

Tubular Frame

Tyre size .........................................................

Front: 90 / 90 - 19” - 52 P

Tyre pressure ...............................................

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

.................................................................

Rear: 120 / 80 - 18” - 62 P

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

Fuel tank capacity ....................................

13.5 Litres ***

Reserve capacity .......................................

2 Litres (approx.)

Dead stock of petrol (unusable fuel) ..

0.75 Litres (approx.)

Suspension ...................................................

Front: Telescopic, 130mm Travel

.................................................................

***Fue l t an k i s n ot a m eas ur i n g instrument. The capacity of tank may vary slightly from specified value.

Rear: Twin gas charged shock absorbers, 80mm travel

Front fork oil capacity ..............................

195 ml per leg

Front fork oil ................................................

1F Endurance (or Royal Enfield) fork oil

Brakes ............................................................

Front : Hydraulic 280 mm Ventilated Disc

.................................................................

Rear : Foot Operated 153mm Single Lead Internal expanding

Brake oil capacity .....................................

60 ml

Brake oil grade ..........................................

DOT 3 or DOT 4 20

TECHNICAL SPECIFICATIONS DIMENSIONS Length ...........................................................

2140 mm

Width ..............................................................

810 mm (Without Mirror)

Height ............................................................

1110 mm (Without Mirror)

Wheel base ..................................................

1370 mm

Saddle height .............................................

800 mm

Ground clearance .....................................

135 mm

N O TE : BS III This vehicle meets Emission Norms Bharat (Trem) Stage - III

WEIGHTS Kerb Weight (with 90% Fuel) ...................

193 Kg

Max pay load .............................................

172 Kg

NOTE 1.

Values / Dimensions given above are for your guidelines only.

2.

In view of continuous improvements being done on our products, the specifications are subject to change without notice. 21

VEHICLE IDENTIFICATION NUMBER - DETAILS FRAME NUMBER

ENGINE NUMBER

Punched on steering head tube RH side.

Punched on top of the engine LH side.

22

KEY PARTS LOCATION 12

TOP VIEW

12

1. Turn signal switch

6

3 4

2. Horn button

7

3. Clutch lever 4. Day flash switch 5. Head lamp dip switch

8

6. Ignition switch 7. Speedometer 8. Front brake lever

1 10 5

2

11

9

9. Accelerator 10. E-Start Switch 11. Fuel tank cap 12. Rear View Mirror

23

KEY PARTS LOCATION RIGHT SIDE VIEW 1.

RH Trafficator Front

2

5

2. Starter Motor

1 3. Brake Pedal

6 4. Kick Starter Lever

4

5.

Air Filter Box

6.

RH Trafficator Rear

3

24

KEY PARTS LOCATION LEFT SIDE VIEW 1. Trafficator Front LH

2

3

4

5

2. Spark Plug 3. Battery Cover

1

4. Electricals Box LH

6

10

9

8

7

5. Rear Shock Absorber 6.

Trafficator Rear LH

7.

Side Stand

8.

Centre Stand

9.

Gear Change Lever

10. 25

Horn

OPERATION OF CONTROLS IGNITION SWITCH

STEERING LOCK

OFF

Turn key clockwise to lock. Lock the steering when leaving bike parked.

Turn key anti clockwise to unlock.

CAUTION ON

Protect your motorcycle against theft. After parking your motorcycle, remove the ignition key from switch and lock the steering head. Turn handle bar to extreme left, before attempting to lock steering. Do NOT lubricate barrel locks with petroleum based lubricants or graphite. Inoperative locks may result in damage to your vehicle. 26

OPERATION OF CONTROLS FUEL TANK CAP

SIDE BOX

Turn key

AIR FILTER BOX RH

clockwise

Turn Key anti-clockwise to open

to open

SIDE BOX LH Press cap to lock with key in position

Turn Key anti-clockwise to open, it contains Tools Kit & Fuse

NOTE NOTE Key can be r em o ved only i n lo ck ed position.

Key is common for ignition, petrol tank cap, steering lock, side boxes and battery cover. Key for fuel tank and tool boxes can be removed from the lock only in locked position. 27

OPERATION OF CONTROLS HEAD LAMP SWITCH

DIP SWITCH

OFF

Low beam

Pilot Light ON

High Beam

Head Light ON

HEAD LAMP DAY FLASH Press for Headlight Flash

28

OPERATION OF CONTROLS ENGINE KILL SWITCH

TURN SIGNAL SWITCH

Run

Left

Stop

OFF (Push to off)

HORN

Right

Press

29

OPERATION OF CONTROLS ENGINE START SWITCH

FUEL TAP

Press

OFF Turn knob to horizontal position

Main ON Turn knob downward position

BATTERY BOX Turn anti clockwise to open Reserve ON Turn knob upward position

30

PRE OPERATIONAL CHECKS A careful check of the following must be carried out every time before riding and specially after long per io ds o f sto r age to d eter m ine if addi ti on al maintenance is necessary.

5. Engine oil level.

MAX MIN

1. Tyres for correct pressure, abrasions or cuts. 2. Rear chain for proper tension. 6. Wh eel

Drive Chain

s po ke

for

proper tightness, no breakage.

Spokes

Clutch

7. Headlamp, tail lamp, brake lamp and indicator 3. B r a k e s , a nd

s teeri ng

th ro tt l e

lamps for proper operation.

fo r

WARNING

responsiveness.

For your personal welfare and safety, all the poi nts m ent io ne d ab o ve s ho u ld b e pe rf or m ed per io di call y. Failu re to do s o, m ay af fe ct s afe operation and damage your motorcycle and could result in an accident causing serious injury.

4. Cable for fraying or cri m ping and f r ee operation. 31

RUNNING IN PERIOD Avoid driving the motorcycle with full throttle o peni ng. Var y the s pe ed o f th e m otor cycl e regularly but avoid using the motorcycle above 3/4 throttle opening position.

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 2,000 kms. During the first few hundred kms, 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.

3.

Avo id prolonged full-throttle operation. Var y speed occasionally.

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

0 - 500 Kms :

Roy al Enfi eld engi nes ar e air- co ol ed a nd consequently require forced air cooling over the cylinders and heads to maintain proper operating temperature. Extended periods of idling may over heat the engine, resulting in serious engine damage.

The recommended speeds for the first 500 Kms is bel ow 5 0 K mph. Dur i ng thi s pe ri od avo id o p erat i ng the m o to rcyc le with f ul l th r ott le opening. Stop the motorcycle for about 5 to 10 minutes to let it cool down, after every hour of run ni ng. Var y the s peed o f t he m o to rcy cle regularly during running but avoid using the motorcycle above ½ throttle opening position. 2.

2,001 kms and above

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.

501 - 2000 Kms. The recommended speed is below 80 Kmph. 32

STARTING Ens ur e Engi ne s to p swi tch is i n “R UN” position

STARTING PROCESS (KS / ES) Turn fuel tap to ‘ON’

Ensur e the side and m ai n st ands ar e in released position Ensure that gears are in neutral and neutral lam p is glo wi ng i n cluster box.

Use cho ke i n co ld condition

CAUTION

N

Do not force the gear lever while attempting to shift to neutral. Move the motorcycle back & forth and simultaneously press gear lever to come to neutral. Ensure neutral indicator light comes “ON”’ in the Speedometer.

Switch on ignition.

WARNING Before starting engine, always shift gears into neutral. 33

STARTING Pres s Star ter Butto n and release as soon as engine starts.

USING KICK START Sl i ghtl y cr ank the en gine fur the r ti ll com pres s ion eas es over.

Release the choke, if applied

Start the motorcycle wi th a po werf ul swinging kick.

NOTE

Release the choke, if applied

A clutch switch is provided in the system for the safety of the rider. This is to prevent the vehicle from starting when the vehicle is in gear. To start the engine when it is in gear, pull clutch lever, press starter button and release as soon as the engine starts.

USING ELECTRIC START

Press starter button and release starter switch once the engine starts.

Press Clutch Lever.

If the engine does not start on the first attempt in cold climate, release the starter button, wait for 30 s econds before pressing the starter button again. 34

GEAR SHIFTING Pre ss th e gear pedal with heel to eng age 2 nd and higher gear.

Warm up engine for 2 minutes - till idling is consistent/ stable

GEA R 1 N

SH IF T PATT ERN 2 3 4 5

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

Press clutch lever towards the hand grip. Press gear pedal with toe to engage 1st gear. Gentl y ope n th ro tt le and rele ase clut ch simultaneously. If clutch is released suddenly, the engine may stall and cause a jerky start.

NOTE

CAUTION

Always move the motorcycle in first gear position only.

T he clutch m us t be ful ly dis enga ged befo re attempting a gear shift. Failure to fully disengage the clutch may cause a jerky start and / OR stalling the engine besi des caus ing damage to tr ansm issi on parts.

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. 35

PARKING PARKING VEHICLE ON CENTER STAND

PARKING VEHICLE ON SIDE STAND

Select a firm, flat surface

Select a firm, flat surface

Hold handle bar straight

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

Lower center stand, and ensure that both the legs of the stand are resting evenly on firm ground. Apply pressure on the fulcrum lever on the center stand and pull vehicle backwards, gently as shown in pic.

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. 36

TOOLS & FIRST AID KIT 1

2

3

4

5

5

6

7

6

1

4 S.No.

Description

Qty.

1.

Tool bag

1

2.

Screw driver O6 X 160

1

3.

Tommy bar

1

4.

Tubular spanner

1

5.

Tool Spark plug

1

6.

Double end spanner 10 X 12

2

3

2

S.No. Description 1. 2. 3. 4. 5. 6. 7.

Antiseptic cream 5 gms Gauze bandage 5 cm x 2 cm Elastic Gauze bandage 8 cm x 1 mtr. Wash proof plaster 1.9 cm x 7.2 cm Sterilized Gauze Swab 5 cm x 5 cm Sterilized elastic plaster 7 cm x 6 cm First aid kit pouch

Qty. 1 1 1 2 2 1 1

NOTE This Tool Kit is kept in Tool box. Refer Page No. 27. 37

RECOMMENDED LUBRICANTS Engine Oil Grade

Royal Enfield 15 W 50 API SL Grade Engine Oil (JASO MA)

Grade

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

Capacity 195 ml/leg

Brake Fluid Grade

DOT 3 or DOT 4

Capacity 60ml

ISO 14001 – EMS Operation Control Process

Capacity 2.75 Ltrs. (with oil filter) 2.50 Ltrs. (during oil & filter element replacement)

WARNING

1. All customers are advised timely replacement of Engine Oil, Fork Oil & Brake Oil at the dealership /ASP. In case done privately, it is advise to reach old/used Oil to our authorised vendor through RE Dealer/ASP 2. Similarly we advise for disposal of old/used Battery, Tube & Tyres as mentioned in above point No.1.

DO NOT s wi tch o il brands indi scriminately because some oil inter act chemically when m ix ed. Use of inferior oils or non-detergent oils can damage the engine. DO NOT Mix DOT 3 & DOT 4 brake fluid together. 38

PERIODICAL MAINTENANCE The maintenance schedule detailed here will help you to maintain your Bullet 500cc 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 Authorised Dealer / Service Point for expert advice and to carry out the periodical maintenance.

WARNING For your personal welfare, all the listed service and maintenance recommendations should be 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. 39

PERIODICAL MAINTENANCE S. No.

FREE SERVICE whichever is earlier Kms (x 1000) 0.5 3 6 9 12

DESCRIPTION

Months

1.5

3

6

9

R

I

R

I

R

PAID SERVICE 15

18

21

24

27

30

I

R

I

R

I

R

1

Engine Oil

2

Engine oil filter element

R

C

R

R

R

R

R

3

Engine sump filter (oil strainer)

C

C

C

C

C

C

C

C

C

C

Check level at every 1000 Kms or earlier as required

5

Magnetic drain plug under gear box and seconC C C dary drain plug under crankshaft in crankcase RH C Spark plugs (2 nos.) C ,A C,A C,A C,A C,A

R

6

HT leads for crack

I

7

Carburetor (C.V. Type)

8

Fuel Tap / Filter

9

Fuel tank

4

I

I

I

I

I

C ,A C ,A C,A C ,A I

I

I

I

R I

*Clean, Inspect and Tune C

C

C

C

C

C

C

C

C

C

C

10 Fuel hose / pipe

I

I

I

R

I

I

I

R

I

I

I

11 Accelerator & Carburetor cable play adjustment

A

A

A

A

A

A

A

A

A

A

A

12 Rubber hose, Air filter to Carburetor

I

I

I

I

R

I

I

I

R

I

I

A : Adjust

C : Clean

D : De-carbonise

I : Inspect 40

L : Lubricate

R : Replace


DESCRIPTION

FREE SERVICE whichever is earlier Kms (x 1000) 0.5 3 6 9 12 Months

1.5

3

6

9

I

I

I

I

13 Rubber hose, Adaptor

R

PAID SERVICE 15

18

21

24

27

I

I

I

R

I

14 Exhaust system

30 I D

15 Air filter paper element

C

C

C

C

R

16 Inlet / Exhaust valve seating

C

C

C

R

C

I

17 Clutch lever free play

C I

Check & Adjust every 1000 Kms or earlier as required

18 Cylinder head (Combustion chamber)

D

19 Hand levers & kick starter lever pivot

Lubricate every 1000 Kms or earlier as required

20 PAV pipes & hose clip

I

I

C

I

C

I

C

I

C

I

C

21 Rear brake pedal pivot

L

L

L

L

L

L

L

L

L

L

L

22 Battery terminals (apply petroleum jelly)

C

C

C

C

C

C

C

C

C

C

C

23 Battery Electrolyte level

I

I

I

I

I

I

I

I

I

I

I

24 Earth wire eyelet (behind battery carrier)

I

25 Front Fork oil / leak A : Adjust

C : Clean

I D : De-carbonise

I : Inspect 41

R

I I L : Lubricate

R

I R : Replace


FREE SERVICE whichever is earlier Kms (x 1000) 0.5 3 6 9 12

DESCRIPTION

Months

1.5

3

6

PAID SERVICE 15

18

21

24

27

9

26 Rear wheel drive chain

Adjust for every 1000 Kms / Clean, Lubricate & Adjustevery 3000 kms or earlier as required

27 Rear brake pedal free play

Adjust every 1000 Kms or earlier as required

28 Rear brake cam

L

29 Steering ball races / play adjustment

A

30 Spokes tightness & Wheel rim run out

I

L

L A

I

R

L A

I

31 Rear wheel cush rubbers

L

L A

I

L

33 Tyre wear (Front & Rear)

R

L A

I

I&R

32 Swing Arm pivot bush & spacer

30

L I

I&R

L

L

R

L

I

I

I

I

I

I

I

R

I

34 Brake fluid (Disc brake)

I

I

I

I

R

I

I

I

R

I

I

35 Pivot-Side Stand, Center Stand, Pillion foot rest

L

L

L

L

L

L

L

L

L

L

L

A : Adjust

C : Clean

D : De-carbonise

I : Inspect

L : Lubricate

R : Replace

NOTE For maintenance after 30,000 Kms, please repeat the same frequency levels specified above, in consultation with a Royal Enfield Authorised Dealer / Service Point. * Refer Service Manual. 42

MINOR MAINTENANCE TIPS The following minor maintenance can be carried out easily with simple tools. However, In case, if it is felt that the adjustments are best done by an expert, we recommend that the motorcycle be taken to a nearest Royal Enfield Authorised Dealer / Service Point.

ENGINE OIL LEVEL INSPECTION

CONTROL CABLES, HANDLE LEVER, PIVOTS, CENTER / SIDE STAND PIVOTS

MAX MIN

Main & Side Stand Pivot

Place motorcycle on its center stand on a firm surface.

Lever Pivot

Warm up engine for a few minutes & switch off.

Lubricate after using the motorcycle in rain, after water wash or if used in dusty conditions.

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

Wipe the area free of dirt / grease. Apply a few drops of oil on the pivots.

Top up with recommended oil if required. 43

MINOR MAINTENANCE TIPS ENGINE OIL CHANGE

Secondary Drain Plug

Primary Drain Cap

TILT VEHICLE RH & LH

Primary Drain Bolt

(Refer Periodical Maintenance Chart for frequency) Place motorcycle on its center stand on a firm flat surface. Start engine and warm up for 2 minutes. Keep a clean tray below the engine. Remove the oil filter element on the Crankcase Cover RH.

Remove primary drain cap, to drain oil & clean suction filter, magnet.

Allow the oil to drain by tilting the motorcycle to both sides. Wash the primary and secondar y drain plugs along with suction filter thoroughly and refit on the crankcase after all the oil is drained out.

Then remove secondary drain plug to drain oil & clean the magnet. Finally remove primay drain bolt to drain the complete oil. 44

MINOR MAINTENANCE TIPS Soak a new oil filter element in the oil and refit on the Crankcase Cover RH.

SPARK PLUG

Assembly 3 bolts and tighten them. Ensure ‘O’ Ring and gaskets are taken seat properly.

C l eani ng a nd a djus ti ng gap (Refer Peri odic al Maintenance Chart for frequency)

Fill recommendedoil to engine till the oil level is upto “M AX ” level mark in the oil wi ndo w i n C ran kcase Cover RH.

Remove HT Lead and the spark plug f ro m the cyl inde r head usi ng t he p lug spanner and tomm y bar as shown in pic. Clean the insulator tip and electrodes of the plug carefully using a poi nted s cr aper or spark plug cleaner.

Max Min

NOTE Replace o il filter elem ent whenever o il is bei ng replaced.

Set the gap between

0.70 to 0.80 mm for UR6DC & 0.80 to 0.90 mm for WQR8DC

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

Refit the spark plug on the cylinder head and connect H.T. Lead. 45

M10

M14

MINOR MAINTENANCE TIPS BRAKE FLUID

INSPECTION OF TYRES AND WHEELS Inspect the tyr e peri odically fo r tread wear, cracks and cuts.

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

Minimum tread depth : Front tyre : 1mm

Rear tyre : 2 mm

Check and remove stone, splinters, nails or other particles embedded in the tyre treads. MAX MIN

Bald spots / swelling may be caused by inte rnal dam age. Rep lace the tyr es , i f defective. Rep lace tyr es w hen the trea d depth has reached the minimum as specified.

CAUTION

Periodically inspect wheels for spokes breakage and wheel rim run out.

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

Check proper seating of the tyre beading on the rim whenever the tyre is reassembled. Whenever a new tyre is installed, ensure rim and spokes do not get damaged on account of using wrong levers.

Don’t mix DOT 3 & DOT 4 Brake fluid together. 46

MINOR MAINTENANCE TIPS Use o nl y standard tyres & tubes infl ated to correct pressure.

FRONT WHEEL REMOVAL Place the vehicle on center stand Place a wooden block th e fr o nt end of engine to support the vehicle.

TYRE PRESSURE

Solo With Pillion

Frontt

Rear

1.41 kg/cm2 (20 PSI)

2.11 kg/cm2 (30 PSI)

1.55 kg/cm2 (22 PSI)

2.25 kg/cm2 (32 PSI)

Dis co nn ect cable.

s peedo

Loosen the pinch bolt on the RH fork guide. Hol d fr ont ax le by spanner and loo sen axle nut then remove nut along with washer.

WARNING Tyres, rims and air valves must be correctly matched to wheel rims. See your Royal Enfield Dealer. Mismatching tyre, tubes, rims and air valves may result in damage to the tyre bead during mounting, allow tyre slippage on the rim and cause tyre failure. 47

MINOR MAINTENANCE TIPS Tap and remove the front wheel spindle

FRONT WHEEL ASSEMBLY

Tilt the vehicle to RH Side and take out the wheel along with speedo drive with bush & LH side spacer.

Remove the wooden piece / card board sheet placed between the brake pads. Pla ce t he b us h sp eedo dr ive i n positi on and place speedo drive over it. In sert the wheel alo ng wit h speedo drive assembly and LH spacer between the fr ont fo rk ends ens ur ing the brake di sc i s lo cat ed i n between the brake pads.

Take out Speedo drive and bush on the RH side as shown in pic.

CAUTION Do not press the front brake lever when wheel is removed as this will result in the brake pads coming too far out of the brake caliper. 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 pressed.

Ins ert and tap the fr ont whee l ax l e gently inside. Refit the washer and tighten the nut firmly. 48

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

Tighten the pinch bolt on the RH fork guide. Rotate the wheel and check for smooth rotation.

Remove wheel spindle fr om LH s ide al ong with chain adjuster, tak ing care no t to drop the wheel collar and spacer from the LH side of the wheel.

Connect the speedo cable to speedo drive unit and rotate the wheel to check for proper working of speedo meter. Press brake lever 2 or 3 times to check front brake efficiency.

Tilt vehicle to RH side and s li de o ut r ear wheel.

NOTE Ensure that the speedo drive is correctly located such that the cable can be connected without difficulty. 49

MINOR MAINTENANCE TIPS Ensure that the chain adjuster knotch butts with the stopper as appropriate when both the front & rear wheels are aligned.

REAR WHEEL ASSEMBLY Ensure the four cush rubbers are in position inside the rear wheel hub.

Tig hten the cas tle nut fir m ly and ensure that the hole o n ax le s ha ft a nd the slot on castle nut are ali gned to en abl e s pl it p in fitment.

Tilt vehicle to right and i nsert wheel assembly between the swing arms. Po s iti o n th e r ear wh eel wi t h cu s h rubber on the rear chain sprocket.

Fix the split pin.

Hold wheel collar and spa cer i n position.

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

A s s em b le t he whe el s pind l e alo ng with chai n adjuster from the LH side of vehicle and gentl y tap it through the wheel.

WARNING Ensure the vehicle does not come off centre stand whi le a ss em bli n g / dis a s sem bl in g th e wh eel assembly. Failure to adhere could result in damage or serious injury. 50

MINOR MAINTENANCE TIPS ADJUSTMENTS - CLUTCH

DRIVE CHAIN FREE PLAY (PLAY 25 - 30 MM)

2 to 3 mm

Remove rear wheel split pin.

A B

Loo sen castle nut, spindle nut, anchor nut and brake rod nut.

Clutch Lever (free play 2 to 3 mm)

CLUTCH FREE PLAY ADJUSTMENT Loosen the cable outer lock nut (A). Turn the RH adjuster cam as appr o priately, till 25 to 30 m m sla ckn es s is achieved on the top run of the chain.

Turn the Nut (B) Clockwise to reduce the play or Anticlockwise to increase the free play. Check free play 2 to 3 mm at Clutch lever pivot on handle bar end. Tighten lock nut (A) after adjustment is done. 51

MINOR MAINTENANCE TIPS Check brake pedal free play, If necessary adjust.

CHECKING REAR BRAKE PEDAL HEIGHT

Check that the front and rear wheels are correctly aligned. Turn the LH adjuster cam appropriately, to ali g n bo th t he wheels. C heck and ensure that the knotches on the cam are resting o n the pi n in t he swing arm on both sides.

Loosen the lock nut.

A p ply bra ke a nd tighten all nuts.

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

Finall y To rque the anchor Nut.

Tighten the lock nut Check for free rotation of rear wheel. 52

MINOR MAINTENANCE TIPS CHAIN LOCK FITMENT

REAR BRAKE PEDAL PLAY ADJUSTMENT

20 - 30 mm Turn in or out the adjuster nut at the brake rod end. The recommended brake pedal travel is 20-30 mm. Check that the brake is not binding and the rear wheel rotates freely.

The open end of the chain link master lock to face opposite to normal direction of chain rotation as shown pic.

WARNING Please ensure brakes are adjusted to their maximum efficiency. Inefficient brakes can cause an accident. Please ensure adequate caution while applying brakes. Sudden application OR pressing the levers fully can caused the wheels to lock. This may cause the motorcycle to skid with possible loss of control and result in an accident causing. Brake shoes must be inspected for wear every 4000 Kms. If you ride under adverse conditions, (steep hills, heavy traffic, etc.) a more frequent inspection at 1600 Kms or less, is required.

WARNING The fitment in wrong direction lock can lead to falling off of chain link thus disengaging the drive. This wil l lead to potentiall y hazardous situati on which, if not avoided, could result in serious injury. 53

MINOR MAINTENANCE TIPS Turn the adjuster such that the adjuster moves up to increase the spring tension and vice versa to reduce the spring tension.

ADJUSTMENT OF GAS FILLED SHOCKABSORBER

RH

A djus t both left hand and ri ght hand s hock absorbers so that the same knotch rests on the pin in both sides.

WARNING Ri ding the m ot or cy cl e wit h th e kn otch es adjus ted in different pos iti ons can cause lo ss of control and may lead to an accident.

LH The rear gas shock absorber is adjustable type i.e., the spring tension can be increased or reduced. Increase the spring tension for high load operation.

Regularly inspect shock absorbers and front forks for leaks. Replace worn parts. Worn parts can adversely affect stability and handling.

Reduce the spring tension for low load operation.

NOTE

The adjuster provided on the bottom of the spring has five knotches.

Ensure no fouling of any accessories with rear shock abs or ber. C h eck f or s uf ficient gap avail abil ity between the shock absorber and the attachments when the rear end of the motorcycle is fully loaded and the shock absorbers are fully compressed.

Insert special ‘C’ spanner on the bottom adjuster and rotate to change knotch position. 54

MINOR MAINTENANCE TIPS BATTERY MAINTENANCE

REMOVAL OF BATTERY ON VEHICLE T he veh icle is provided with 12V 14 AH battery.

The battery must be periodically checked for

Unlock (turn the key anti clockwise) and remove the battery cover.

C l eanl i ne ss a nd cor ro si o n f r ee terminals. Electr o l yte lev el m us t be abo ve “MIN” level.

Remove the battery holding two rubber straps gently.

If electrolyte level is lo w, r em o ve caps and top up with distilled water only.

Pull out the battery an d t urn , th en disconnect both the ter m i na l wi r es (ne gati ve a nd positive respectively)

Apply petroleum jelly o v er t he b atter y ter m i na ls t o av oid sulphation.

Take out the battery. 55

MINOR MAINTENANCE TIPS WARNING

ASSEMBLY OF BATTERY ON VEHICLE

Always disconnect the negative (-) battery cable fi rs t and then the Red pos iti ve (+) cable while removing the battery connections.

Position the battery in the battery carrier such that the negative terminal of the batter y is towards fuel tap.

NOTE

Ensure ignition switch is in ‘OFF’ condition.

For checking the battery voltage and electrolyte specific gravity, contact authorised Royal Enfield service or battery service centre.

Connect the positive terminal (Red wire) first. Connect the negative terminal (Black wire) next. Smear the terminals with petroleum jelly. (Do not use grease).

CAUTION

Refit the rubber strap bracket to hold the battery.

Do not use battery with low electrolyte level as the battery internals cells will get damaged.

Refit LH side panel.

Do not overfill the battery electrolyte level as it will spill out through the overflow pipe and cause corrosion to vehicle parts.

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

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

CAUTION

Electrolyte should not be filled when the level is between minimum & maximum levels indicated in battery as “MIN” & “MAX”.

Connect the +ve and -ve cables to the respective batter y terminals. Failure to do so may result in damage to the motorcycle electrical system. 56

MINOR MAINTENANCE TIPS Remove rubber grommet fr om the r ef lecto r Assembly.

CHANGING ELECTRICAL COMPONENTS HEAD LAMP BULB REPLACEMENT Lo o sen the hea d la m p holding top screw. Then pul l out head lam p assembly.

Gen tl y pr es s th e bu l b holding ‘U’ clip from both the sides downwards and releas e it from reflecto r slot as shown.

Detach bo ttom lug fr om the head lamp ho us ing body.

Pull out head lamp bulb and inspect its filament for fuse.

CAUTION

Di sco n nect hea d la m p wir e co nnec to rs Gre en, Ora nge and Blue co l o r terminals.

Never to uch the bul b wi th your fingers, Finger prints will etch the glass and decrease bul b lif e. A lways ho ld the bulb with paper or clean dry cloth during handling. 57

MINOR MAINTENANCE TIPS Connect the wire couplers as mentioned below.

ASSEMBLING THE HEADLAMP Refix the new head lamp hal ogen bul b in to reflector unit by locating the wide protrude on top side mounting.

TOP SIDE: GREEN COLOUR RIGHT SIDE: BLUE C OLOUR LEFT SIDE: ORANGE COLOUR

Position the reflector ring bottom lug into head lamp cas ing slo t and sl ide it, th en t i ght en t he t o p mounting screw.

Fix bulb holding U clip into ref l ect o r b o dy kno t ch, then press the both ends of clip and lock in its slot.

NOTE After connecting above said procedure, turn ignition switch to “ON” condition and then check, ensure that flash light working in HIGH BEAM mode.

Fit the rubber grommet.

If you use the bulb other than specified rating (12V 55/60W) may result in over loading electrical system lea d to pre m atu r e f ailu re o r fr eque nt b atte r y discharge. 58

MINOR MAINTENANCE TIPS TAIL LAMP BULB REPLACEMENT

TRAFFICATOR BULB REPLACEMENT

Remove the two nuts each from RH & LH side of the rear number plate holder.

Remo ve the 2 screws & take out trafficator glass cover.

Pul l ou t Ta il Lamp as s em b ly a lo n g wi th bracket and twist the bulb holder in anticlockwise to re m ove bulb holder assembly.

Press bulb gently & Turn anticlockwise to take out the bulb. Po s iti o n th e ne w bu lb ins i de the ho ld er, ensuring that the pins in the bulb, match with the slots in the holder.

Turn old bulb to remove and replace with a new bulb. Refit the bulb holder and turn clockwise to lock the bulb holder.

Pres s the bulb and turn clockwise to lock the bulb in the holder.

Ref it the tai l la mp wi th b rack et on t he reverse order of removal process.

Refit the trafficator cover cu t s l o t m ar k faci ng downwards and tighten the 2 screws. 59

Cut Mark

MINOR MAINTENANCE TIPS Replace the required fuse with the spare fuse available in the fuse carrier.

FUSE Open the LH tool box.

NOTE

Take out tool kit.

Please ensure to replace a spare fuse in the holder at the earliest opportunity.

Remove fuse holder rub ber & l i ft f us e carrier top cover.

BLADE FUSE USAGE LIST Fuse No.

4

Color

Remarks

1

Blue

Main Fuse (15A)

2

Red

Ignition Fuse (10A)

3

Red

Spare Fuse (10A)

4

Blue

Spare Fuse (15A)

3 2 1

60

MINOR MAINTENANCE TIPS Tap the filter element to r em o ve d ust as sh o wn and cle an tho ro ug hl y befo r e assembly.

AIR FILTER PAPER ELEMENT CLEANING/REPLACEMENT Insert the key, turn an ti cl okw ise to remove RH side air filter box lid.

Clean both intake adaptors and duct as shown in pic.

Loo sen the fil ter hol di ng nut by 10mm spanner as shown in pic.

Assemble the filter element and cover in the reverse order of dismantling process.

Rem o ve the nut, washer and co ver air filter to take out air filter element.

Please ensure proper sealing of cover plate against air filter element. 61

WASHING PROCEDURE AFTER WASHING

PRECAUTIONS Wash vehicle 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 vehicle. Never spray water with great force on head lamp, speedometer, trafficator lights, front and rear wheel hubs, electrical connections and wires, control cables, sparkplug, battery, etc. Use luke warm water and mild detergent on the painted components to remove dirt, etc. Rinse vehicle thoroughly with plain water to remove the detergent and wipe vehicle dry. If possible, use compressed air and blow off water particles from the obscure areas of the vehicle, electrical connections etc.

Ensure, the vehicle 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. Start the bike allow engine to idle and warm up. 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. 62

STORAGE PRECAUTIONS Rem o ve bat ter y f ro m t he b ike. C le an t he terminals free of corrosion.

Incase your Motorcycle is not going to be used for a month or more, we advise the following precautions to the taken.

Maintain electrolyte level between max or min mark, by adding distilled water and wipe the battery dry.

Carryout required repair / adjustments on the motorcycle.

Sto r e t he b atter y i n a co ol , dr y an d wel l ventilated place.

Wash the motorcycle thoroughly and lubricate as per the maintenance chart.

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

Start the engine, warm up for a few minutes and switch off. Drain out the fuel completely from the fuel tank and fuel lines.

Cover the silencer with plastic bags to prevent moisture entry. Set the motorcycle on its center stand.

Remove spark plug. Pour in about 25ml of clean engine oil through spark plug hole. Close the hole an d cr ank engi ne s ever al t im es and r ef i t sparkplug.

Apply anti rust solution on all chrome pl ated par ts. 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.

Clean rear chain thoroughly and apply a thin film of lube oil. 63

STORAGE PRECAUTIONS Remove spark plug on cylinder head and pour

PREPARING THE MOTORCYCLE FOR RE USE

in a few drops of engine oil. Crank engine a few

Remove anti rust solution from all chrome plated

ti mes to lubricate cylinder walls and piston.

parts and clean the motorcycle.

Clean spark plug and refit.

Inflate the tyres to the correct tyre pressure.

Switch “ON” ignition switch.

Ens ur e batter y i s fully charged and pr oper

Star t vehicle and warm up engine fo r a f ew

electrolyte level is maintained.

minutes before riding the vehicle.

Connect the battery. Lubricate all control cables and pivots. Check proper level of oil in engine.

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

Fill fuel tank with fresh petrol. Check fuel line / hose for any cracks or cuts.

CAUTION

Clean the air filter.

Proper long-term storage is important for the safe, tr oubl e-fr ee o per a tio n of your Roy al E nfie ld motorcycle.

Remove plastic covering from the silencer. 64

LONG TRIP PRECAUTIONS CHECKS PRIOR TO THE COMMENCEMENT OF LONG JOURNEY

ITEMS TO BE CARRIED Tool kit.

Ser vice the m otor cycle tho ro ughly at Ro yal Enfield Authorised Dealer / Service Point as per periodical maintenance chart. (Ref. Page No. 40, 41 & 42)

First aid kit. Bulbs for Headlight, Trafficator light, Rear Tail Lamp and Fuse (10 & 15 Amps).

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

Accelerator, Clutch and Speedo Cable.

Check and correct tyre pressure if necessary.

Rear chain master link lock assembly.

CHECKS AFTER EVERY 1500 KMS OF RUN Tightness of all fasteners.

Spare tube, puncture repair kit - cold vulcanising

Tyre tread condition and wear of tyres.

type.

Battery condition and electrolyte level.

Foot operated Air Pump.

Correct oil level in engine. Insulation tape.

Working of all lights and horn. Proper drive chain tension.

Spark plugs (M14 & M10), Fuel hose. 65

CARING FOR MILEAGE Both lower and higher road speeds cause low kilometers per litre of petrol.

STOP THE DROP THAT LEAKS Petrol leak at a rate of one drop per m inute accumulates to 5,25,600 drops a YEAR! That is, 35 ltrs of Petrol.

PERFORM PREVENTIVE MAINTENANCE AS PER RECOMMENDATIONS

Petrol leaks cause raw petrol smell. Get the leaks arrested immediately.

REGULAR PREVENTIVE MAINTENANCE ENSURES Correctly inflated tyres.

USE RECOMMENDED FUELS AND OILS ONLY

Fasteners tightened to correct torques.

Wrong grade or adulterated petrol does not burn fully and results in heavy smoke, high rate of car bo n depos iti on i n cylinder and exhaus t system and low mileage.

Freely moving engine & transmission components. Properly tuned and adjusted engine.

CUT OFF NEEDLESS LOW IDLING

Wrong grade and inferior quality oils do not lub rica te w ell. T he m ov ing part s we ar prematurely.

Ten minutes of low idling wastes 70 ml. of petrol. So cut off the engine when you know you have to wait for one minute or more.

Always use recommended fuel (unleaded > 87 octane petrol) and oils only.

STOP Revving : Ten revvings wastes 20 ml. of petrol

RIDE AT COST EFFECTIVE SPEED

Racing starts : Ten racing starts wastes 150 ml. of petrol.

Cost effective speed (in top gear) is 45 to 50 Km per hour. 66

CARING FOR MILEAGE Sudden acceleration : Ten sudden accelerations wastes 100 ml. of petrol.

For better mileage, use front and rear brakes simultaneously when absolutely needed. Control vehicle speed with throttle and gear like smart riders always do.

STOP BRAKE RIDING Brake riding pushes the brake shoes to come in contact with revolving drum. To overcome the resulting frictional load, engine burns additional petrol.

AVOID OVER LOADING Over loading tyres the engine, wears the parts faster and reduces mileage.

Result : Low mileage, loss of power, faster wear of brake shoes and drum.

PARK YOUR VEHICLE IN SHADE WHEN NOT IN USE Petr ol is highl y volatile. It evaporates under no r m al atm os ph er ic te m per atur e. T he evaportion increases with temperature. Prevent this loss by always parking your vehicle under shade.

NEVER CLUTCH RIDE Clutch riding slips the clutch & engine drive does not get totally transferred to the rear wheel. Besides low mileage, clutch riding ends up with burnt friction plates of clutch, loss of power and engine overheating.

Too few Kms running per day allows more time for evaporation affecting the mileage.

AVOID FREQUENT BRAKING Braking arr ests the ro ad s peed. M otorcycl e momentum is reduced. Additional fuel is burnt for subsequent acceleration. 67

COMPLETE WIRING DIAGRAM - BULLET 500 NOTE : Complete Wiring Diagram is attached on this page.

VEHICLE STARTING PROCEDURE BASIC GUIDELINES TO BE FOLLOWED “FOR ALL ELECTRIC START VEHICLES” 1.

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

2.

Apply choke in cold start condition. (ambient temperature 87 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. 82

ALL INDIA ROAD SIGNS MANDATORY SIGNS

CAUTIONARY SIGNS

INFORMATION SIGNS

83

FREE SERVICE COUPONS It is our endeavour to provide excellent service to your Royal Enfield Motor Cycle at all times. Towards this we provide four free services at specific Intervals. Please avail these services at the specified time, in any of the Royal Enfield Authorised Dealer / Service Point nearest to you and as a token of satisfactory service, kindly return the free service coupon duly filled in and signed, to the service outlet. Availing the free services in the specified time is a prerequisite to warranty consideration.

84

1ST FREE SERVICE

1ST FREE SERVICE

500 KMS OR 45+8 DAYS WHICHEVER IS EARLIER FROM DATE OF SALE Customer Name :

Dealer Code :

Address :

500 Kms or 45+8 days whichever is earlier from the date of sale

Frame No:

Regn. No:

Engine No:

Sale Date:

Vehicle Installation Form No.

Serviced Date:

ODO Reading :

Serviced by (Dealer’s/ASP Name & Address)

Enter the Details in Free Service Record

Sold by (Dealer’s Name & Address)

(Cost of oil, oil filter element and other consumables used are chargeable to the customer)

Received the above vehicle after the service having been done to my entire satisfaction. Customer’s Signature : ................................. Contact Phone / Mobile No.: 85

Date :

1ST FREE SERVICE ACTIVITIES 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.

Water wash the vehicle and dry it with a clean cloth Electrolyte ...................................................... Check level & top-up Battery terminals ......................................... Clean and apply petroleum jelly Drive chain free play ................................. Check, clean, lubricate & adjust Rear brake pedal pivot ............................ Lubricate Rear brake .................................................... Adjust Wheel rims front & rear ............................. Check spokes tightness Front & Rear brake ..................................... Check & Adjust Front fork oil leak ......................................... Check for leakage Air filter element .......................................... Clean Spark plugs (2 Nos) .................................... Check, clean & adjust gap H.T. Leads ...................................................... Inspect for cracks Carburetor .................................................... Drain & Tune Fuel filter ........................................................ Clean Fuel hose ........................................................ Inspect for cracks Rubber hose, Air filter to carburetor ..... Inspect for cracks Accelerator cable ....................................... Check & adjust play Clutch cable .................................................. Adjust play Engine oil sump strainer ........................... Clean Engine oil ....................................................... Replace Engine oil filter element ............................. Replace Hand levers & kick starter pivot .............. Lubricate 86

CUSTOMER COPY Job Card No:

Date :

Odo Reading : Name of Dealer/ ASP with Code: .......................... ..........................

ASP / Dealer’s Stamp & Signature

2ND FREE SERVICE

2ND FREE SERVICE


Dealer Code :

Address :


Frame No:

Regn. No:

Engine No:

Sale Date:


Serviced Date:

ODO Reading :






Date :

2ND FREE SERVICE ACTIVITIES 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.

Water wash the vehicle and dry it with a clean cloth Electrolyte ...................................................... Check level & top-up Battery terminals ......................................... Clean and apply petroleum jelly Drive chain free play ................................. Check, clean, lubricate & adjust Rear brake pedal pivot ............................ Lubricate Rear brake .................................................... Adjust Wheel rims front & rear ............................. Check spokes tightness Front & Rear brake ..................................... Check & Adjust Front fork oil / leak ....................................... Check for leakage Air filter element .......................................... Clean Spark plugs (2 Nos) .................................... Check, clean & adjust gap H.T. Leads ...................................................... Inspect for cracks Carburetor .................................................... Drain & Tune Fuel filter ........................................................ Clean Fuel hose ........................................................ Inspect for cracks Rubber hose, Air filter to carburetor ..... Inspect for cracks Accelerator cable ....................................... Check & adjust play Clutch cable .................................................. Adjust play Steering free play ....................................... Check & Adjust Engine oil ....................................................... Check level & top-up Hand levers & kick starter pivot .............. Lubricate Clean Oil filter element, oil strainer & magnetic drain plugs. 88


Date :



3RD FREE SERVICE

3RD FREE SERVICE


Dealer Code :

Address :


Frame No:

Regn. No:

Engine No:

Sale Date:


Serviced Date:

ODO Reading :






Date :

3RD FREE SERVICE ACTIVITIES 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25.

Water wash the vehicle and dry it with a clean cloth Electrolyte ...................................................... Check level & top-up Battery terminals ......................................... Clean and apply petroleum jelly Drive chain free play ................................. Check, clean, lubricate & adjust Rear brake pedal pivot ............................ Lubricate Rear brake .................................................... Cam clean, lubricate & Adjust play Swing Arm Bush & Spacer ........................ Lubricate Wheel rims front & rear ............................. Check spokes tightness Front & Rear brake ..................................... Check & Adjust Tyres front & rear ........................................ Check wear and tread depth Air filter element .......................................... Clean Spark plugs (2 Nos) .................................... Check, clean & adjust gap H.T. Leads ...................................................... Inspect for cracks Carburetor .................................................... Clean, O/H & Tune Fuel filter ........................................................ Clean Fuel hose ........................................................ Inspect for cracks Rubber hose, Air filter to carburetor ..... Inspect for cracks Accelerator cable ....................................... Check & adjust play Clutch cable .................................................. Adjust play Engine oil sump strainer ........................... Clean Engine oil ....................................................... Replace Engine oil filter element ............................. Replace Hand levers & kick starter pivot .............. Lubricate PAV System ..................................................... Check & Clean Steering System ............................................ Check, Lub. steering balls & adj. play 90


Date :



4TH FREE SERVICE

4TH FREE SERVICE


Dealer Code :

Address :


Frame No:

Regn. No:

Engine No:

Sale Date:


Serviced Date:

ODO Reading :






Date :

4TH FREE SERVICE ACTIVITIES 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23.

Water wash the vehicle and dry it with a clean cloth Electrolyte ...................................................... Check level & top-up Battery terminals ......................................... Clean and apply petroleum jelly Drive chain free play ................................. Check, clean, lubricate & adjust Rear brake pedal pivot ............................ Lubricate Rear brake .................................................... Adjust Wheel rims front & rear ............................. Check spokes tightness Front & Rear brake ..................................... Check & Adjust Front fork oil / leak ....................................... Check level & replace oil Air filter element .......................................... Clean Spark plugs (2 Nos.) ................................... Check, clean & adjust gap H.T. Leads ...................................................... Inspect for cracks Carburetor .................................................... Drain & Tune Fuel filter ........................................................ Clean Fuel hose ........................................................ Inspect for cracks Rubber hose, Air filter to carburetor ..... Inspect for cracks Accelerator cable ....................................... Check & adjust play Clutch cable .................................................. Adjust play Engine oil strainer ....................................... Clean Engine oil ....................................................... Check level & top-up Hand levers & kick starter pivot .............. Lubricate Steering free play / system ....................... Check and Lubricate Steering Balls & Adjust Tyres ................................................................ Check wear and tread depth 92


Date :



PAID SERVICE / MAINTENANCE RECORD CUSTOMER COPY

DEALER / ASP COPY

12,000 + 250 Kms. Service


Job Card No :.................Date : .........................

Job Card No :.................Date : .........................

Odo Reading : ................. Dealer Code : .............


Brief Work Done :

Brief Work Done :

Dealer’s Stamp & Signature


CUSTOMER COPY

DEALER / ASP COPY



Job Card No :.................Date : .........................

Job Card No :.................Date : .........................



Brief Work Done :

Brief Work Done :



93

PAID SERVICE / MAINTENANCE RECORD DEALER / ASP COPY

CUSTOMER COPY



Brief Work Done :

Brief Work Done :



DEALER / ASP COPY

CUSTOMER COPY



Brief Work Done :

Brief Work Done :



94


DEALER / ASP COPY



Job Card No :.................Date : .........................

Job Card No :.................Date : .........................



Brief Work Done :

Brief Work Done :



CUSTOMER COPY

DEALER / ASP COPY



Job Card No :.................Date : .........................

Job Card No :.................Date : .........................



Brief Work Done :

Brief Work Done :



95


CUSTOMER COPY



Brief Work Done :

Brief Work Done :



DEALER / ASP COPY

CUSTOMER COPY



Brief Work Done :

Brief Work Done :



96


DEALER / ASP COPY



Job Card No :.................Date : .........................

Job Card No :.................Date : .........................



Brief Work Done :

Brief Work Done :



CUSTOMER COPY

DEALER / ASP COPY



Job Card No :.................Date : .........................

Job Card No :.................Date : .........................



Brief Work Done :

Brief Work Done :



97


CUSTOMER COPY



Brief Work Done :

Brief Work Done :



DEALER / ASP COPY

CUSTOMER COPY



Brief Work Done :

Brief Work Done :



98


DEALER / ASP COPY



Job Card No :.................Date : .........................

Job Card No :.................Date : .........................



Brief Work Done :

Brief Work Done :



CUSTOMER COPY

DEALER / ASP COPY



Job Card No :.................Date : .........................

Job Card No :.................Date : .........................



Brief Work Done :

Brief Work Done :



99


CUSTOMER COPY



Brief Work Done :

Brief Work Done :



DEALER / ASP COPY

CUSTOMER COPY



Brief Work Done :

Brief Work Done :



100

LOG BOOK Sl. No.

Date

Kms.

Idling Co%

Details

101

Authorised Dealer / Service Point Stamp & Job Card No. Signature

LOG BOOK Sl. No.

Date

Kms.

Idling Co%

Details

102


LOG BOOK Sl. No.

Date

Kms.

Idling Co%

Details

103


LOG BOOK Sl. No.

Date

Kms.

Idling Co%

Details

104


LOG BOOK Sl. No.

Date

Kms.

Idling Co%

Details

105


NOTES

106

NOTES

107

NOTES

108

Telephone Residence Bike Regn. No. Telephone Office

Invoice No.

E

Delivery Note / Advice No.

Sales Representative or

Have you visited Royal Enfield website?

Yes

No

PRE DELIVERY INSPECTION LIST MODEL: BULLET 350 / ELECTRA / CLASSIC 350 / CLASSIC 500 / BULLET 500 Model :

Engine No:

Dealer's Name :

Location:

Colour :

Key Number : Battery Make :

Battery Number : Aggregate CHASSIS / ENGINE NUMBER

Tyre Number : Defect Code

Area 1

CONNECT BATTERY / 2 CHECK VOLTAGE

Measure

Engine / Vehicle Number Details

DF

Same

Battery Charging

D / NC / Weak Battery Voltage 12V-whereas 13.5 V (Max. online voltage) Cell

3

Fill 2.5 Litres (Capacity is Replace oil & oil filter / Check Oil level (3 Drain EO - (Drained 2.75 Litres) - Remove 3 Bolts system Hex 19mm, 8mm X 2nos and Oil Level) Drain Bolts to Drain the Hex 12mm head bolts) complete Oil

ENGINE OIL 4

Clean Primary Oil Strainer screen

-

Clean

LOCK OPERATION

5

Ignition / Side Air Filter Box / Tool Box Lock / Fuel Tank Lock

H / LF / NW

Same

PETROL

6

Fill Petrol

-

5 Litres

7

Brake Lever Free Play

EP / T

2-3 mm / (STD)

8

Caliper Mounting Bolts

LF

2.7 to 3.0 Kgm

9

Front Wheel Rotation

W / T / LF / N

Free ( Check Spokes Looseness & Runout

10

Front Mudguard Alignment / Cover Tube Rubbing

M / RB

Straight

LF

7.0 to 7.7 Kgm

FRONT WHEEL

11 Front Wheel Nut

12 Front Tyre Condition (Check Tyre Line Seating) WF

Good

13 Front Tyre Pressure

LESS

22 PSI

14 Clutch Operation

H/N

Smooth

15 Clutch Lever Free Play

EP / V / T

2 - 3 mm

16 Accelerator Operation

T / SY

Smooth

17 Lever Brackets Tightness

LF

Tight

18 Switch Modules Tightness

LF

Tight

T

Free

WF

W.r.to Dot Punch

LF

4.5 to 5.5 Kgm

22 Electrical Switch Operation

NW / F

No Defects

23 Neutral Lamp

NW / F

No Defects

24 Fuel Tap Operation

H / NW

Smooth / Main / Reserve

25 Fuel Leak

L

No Leak ( Tank, Tap, Carburetor)

26 Fuel Tank Alignment

M

Straight

27 Rear Brake Pedal Free Play

T / EP

20 - 30 mm

28 Pedal Position w.r.t foot rest

DF

Same Level

29 Chain Tension

T / EP

20 - 25 mm

30 Rear Wheel Rotation

W / T / LF / N

Free (Check Spokes Looseness & Runout)

31 Anchor Pin Nut

LF

4.5 Kgm

32 Rear Mudguard Alignment

M

Straight

33 Rear Tyre Pressure

LESS

32 PSI

CLUTCH

HANDLE BAR 19 Steering Movement CONTROLS & ELECTRICAL SWITCH 20 Handle Bar Positioning OPERATIONS 21 Lock Nut T- Stem

FUEL SYSTEM

REAR WHEEL

34 Rear Tyre Condition (Check Tyre Line Seating) WF

Good

35 RR Shock Absorber Operation / Adjustment

Smooth

H / N / AD

Front : Defect Defect Defect #1 #2 #3

Rear : Remarks

36 Mudguards - Paint / Plating Related

SC / PD / R / DN

No Defects (Mudguards / Fuel Tank / Tool Box

37 Fuel Tank - Paint Related

SC / PD / R / DN

No Defects

38 Tool Box LH, Air Filter Box, Battery Cover Paint / Plating Related

SC / PD / R / DN

No Defects

39 Head Lamp Casing - Paint Related

SC / PD / R /

No Defects

SC / PD / R

No Defects

41 Plated Parts (Scratch / Rusty)

SC / R / PO

No Defects (Mudguards / Fuel Tank / Wheel Rim / Indicator

42 Buffed components poor Buffing & Scratches

SC / DU

No Defects

43 Seat Alignment

M

No Defects

44 Indicators Alignment (MFR / Amber)

M

No Defect / Colour

45 Stickers / Knee Pads

M / LF / SC

No Defects

46 Nuts, Bolts, Fasteners (Torque)

LF

Tight (RH, LH Cover / Engine Foundation / Accessories / Wheel Nut)

47 Owner's Manual & Tool Kit Content

-

Availability

48 Spare Fuse in Fuse Carrier

NA

Tubular / Blade Fuse

49 Starting (Kick Start / Self Start)

ST / N

Easy Start

50 Front / Rear Brakes Effectiveness / Feel

AD / SG

Sharp

51 Pulling

P

Straight

52 Vibration

V

Smooth

53 Wobbling

W

No Defects

54 Front Fork / Drive Chain Noise

N

No Defects

55 Engine Performance / Gear Shifting / TPS Setting

N / ST / J / H

Smooth

56 Any Rattling / Squeaking Noise

N

Nil (Silencer / Accessories / Body Parts / Suspension)

57 Easy Start (Hot Condition)

ST / NW

Smooth

58 Leak

L

No Leak (Oil / Fuel / Hydraulic / Acid Leakage)

59 Smoke / Oil Droplets in Silencer

SK / EO

No Smoke

60 Cam Noise / Top End Noise

N

Smooth

40

AESTHETICS

Powder Coated Parts (Scratch / Rust / Chipped OFF)

OTHERS

TEST RIDE

STATIC CHECK (AFTER TEST RIDE)

Lens Colour Check

ANY OTHER

Any Abnormal Noise or Engine Open cases during PDI Inform to Plant / Factory

Note **

INSTRUCTIONS

1. Check the vehicle thoroughly for any transit damages or shortage of parts.

4. Please ensure delivery of the vehicle in brand new condition.

2. Carry out all jobs listed under Pre-delivery Inspection Schedule.

6. Claim Parts replaced for Manufacturing defects only under warranty.

5. Claim transit loss and damage through ‘TRANSIT’ insurance only.

3. Thoroughly road - test the vehicle for performance. Misalignment

Noise

Vibration

Leak

Starting Trouble/Missing

Less

Wobbling

Loose Fitment

Discharing

Tight

Fused

Scratch

Pulling

Dent

Wrong Fitment

Hard

Jerking

M

N

V

L

ST

LESS

W

LF

D

T

F

SC

P

DN

WF

H

J

Excess Play

Different

Spongy

Sticky

Not Available

Smoke

Adjustment

Not Working

Paint Defect

Rust

Peel Off

Dull

Excessive Oil

Rubbing

Not Charging

EP

DF

SG

SY

NA

SK

AD

NW

PD

R

PO

DU

EO

RB

Format No : F/14A/CS/02, Mar. 2013

NC

DLR / CS COPY

BIKE INSTALLATION CONFIRMATION BY CUSTOMER We congratulate you on becoming a proud owner of Royal Enfield bike. We request you to give this feedback after completion of the delivery process. YES 1 2 3 4 5 6 7 8 9 10 11 12

Bike Documents explained (Invoice, Insurance, RC / Road Tax Receipt) Owner’s Manual received Recommended Lubricants explained Maintenance Schedule sheet in Owner’s Manual shown and explained Next Free Service due explained All Free / Paid Services explained Warranty Guidelines explained “Running in period” details shown in the manual explained Service Station Address given and Location explained Service Incharge Name & Mobile No given Bike delivered in neat and clean condition Tool Kit & First Aid Kit received and explained

NO

YES 13 14 15 16 17 18 19 20

NO

Control Switches & Disc Brake System usage explained Fuse Box location shown and explained Recommended Tyre Pressure explained Bike starting & Gear shifting procedure explained Quantity of Fuel in Fuel Tank informed Bike orientation & short distance drive provided Date and Time of Installation Name of Person who did Installation

Suggestions If Any: CUSTOMER SIGNATURE Model:

Registration No.:

Chassis No.: We thank you and request you to return this filled up form to the person who did the bike installation for you KEEP RIDINGP

FORM 22 [See Rules 47(g), 115, 124 (2), 126A and 127 (1), 127 (2)] INITIAL CERTIFICATE OF COMPLIANCE WITH POLLUTION STANDARDS, SAFETY STANDARDS OF COMPONENTS AND ROAD WORTHINESS Certified that the following vehicle complies with the provisions of the Motor Vehicles Act, 1988, and the rules made there under, including the following mass emission norms: Bullet 500

Brand name of the vehicle

:-

Chassis number

:-

Engine number/motor number (in case of battery operated vehicles)

:-

Sub-rule No. of rule

:-

115(2)(i), 115(14)(F)

Emission norms [Bharat Stage-I/II/III/Bharat (Trem) Stage-III etc.]

:-

Bharat Stage III

Date :

For ROYAL ENFIELD

Quality Assurance