Royal Enfield BULLET TRIALS 500 Owner's manual

BULLET TRIALS 500 - EURO IV

FOREWORD

Congratulations! Now you are a part of the most enduring tale in motorcycling!

Bullet, introduced in 1932, the world’s oldest motorcycle model in continuous production, is at the heart of the

Royal Enfield’s storied heritage. The Bullet Trials Works, arriving at 1948 Colmore Cup Trials with their rear

swinging arm suspension, dominated the Trials competitions across Europe for the next decade and changed

the way motorcycles were designed since. Hugely successful in the competitions that tested endurance & resilience,

Bullet Trials Works Replicas were subsequently made available for the public and caught the interest of the

army of a newly independent nation, tasked to patrol a long border of arduous terrains. To know more about

this and the exciting world of Royal Enfield, please log on to www.royalenfield.com

This manual will help you to operate your Bullet Trials Replica, came to be known as Trials Bullet, the right way

and guide you to maintain your motorcycle meticulously. We have also provided tips on safe riding and on

minor adjustments for the care of your motorcycle. Please do avail of all the services at your nearest Authorised

Service Centre to make sure that your motorcycle gets the right treatment which it so deserves. Please also read

through the terms and conditions of warranty and other useful information in this manual before riding into the

world of pure motorcycling.

Keep riding.

2

All information in this manual is based on the latest product information available at the time of publication.

Due to continuous improvements, there may be discrepancies between the information in this manual and your

motorcycle. Royal Enfield reserves the right to make production changes at any time without prior notice and

without incurring any obligation to make the same or similar changes to motorcycles previously built or sold.

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

Technical specifications are subject to change without prior notice.

copied, distributed or otherwise dealt without the express permission in writing of Royal Enfield”.

NOTICE

Part No. RAM00069/A / Qty. 200 / Mar. ‘19

Disclaimer

Applicable for all Matt finish motorcycles

1. Do not polish matt finished paint surfaces in your motorcycle as it will increase the

gloss level.

2. Wash the painted parts only with plain water and do not use any strong solvents,

cleaning agents or detergents.

3. Scratches, if happens on the matt finish parts cannot be touched up and corrected

/ removed

4. Warranty is not applicable for any matt finished painted parts of the motorcycle.

5. The Heat Resistance Coated components such as silencer pipe, exhaust etc... shall

not be wiped clean with oiled cloth as it can generate smoke when the vehicle is

driven and also leave patch marks.

3

CONTENTS

Personal and Motorcycle Information 4

Safe Operating Rules 5

Rules of the Road 11

Technical Specifications 13

Recommended Lubricants 16

Safety Definitions 17

Motorcycle Identification Numbers 18

Location of Key Parts 19

Operation of Controls 22

Pre-Operational Checks 26

Safe & Happy Riding 27

Running in Period 28

Warning Indication & Safety Systems 29

Starting 34

Gear Shifting, Riding & Stopping 35

Parking 36

Periodical Maintenance Chart 37

Tools kit 40

Wheel Removal & Assembly 41

Minor Maintenance Tips 45

Long Trip Precautions 56

Washing Procedure 57

Storage Precautions 58

Trouble Shooting 59

Warranty Terms & Conditions 61

EVAP 63

Environment Care 65

Service Maintenance Record 67

Notes 71

4

PERSONAL & MOTORCYCLE INFORMATION

Name

Door No./Street

Locality

City State Pin

Contact Nos. Res: Off: Mobile : Email :

Engine No. Battery No.

Frame No. Battery make

Reg. No. Licence No.

Date of Sale Valid till dt.

Model Key No. :

Tyre make Colour

Sold by Dealer Code

5

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.

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

rider for your own safety and for other road users.

Before starting the motorcycle, check for proper

operation of brakes, clutch, gear shifter, handle

bar controls, tyre pressures, fuel and oil levels.

SAFE OPERATING RULES

W A R N I N G

Use only genuine Royal Enfield spare parts

and approved accesso ries. Use of other

manufacturer’s performance parts may affect the

performance of your motorcycle and render the

motorcycle void of warranty. See your Royal

Enfield Authorized Dealer for details.

Whenever refuelling your motorcycle, please

exercise utmost caution and carefully observe the

following rules :

HDO NOT smoke and please ensure that there

are no open flames or sparks near the

motorcycle, when refuelling OR servicing the

fuel system.

HSwitch OFF mobile phones and other hand

held electronic devices.

HOpen the fuel filler cap slowly.

HRefuel in a well ventilated area with the engine

turned off.

Royal Enfield cautions you against the use of certain

nonstandard parts such as aftermarket and custom

made extended front forks or suspensions, which may

adversely affect performance and handling.

Removing or altering original parts may adversely

affect performance and could result in an accident

causing serious injury.

6

SAFE OPERATING RULES

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

riders should gain experience under various

conditions while driving at moderate speeds.

Gasoline is extremely flammable and highly

explosive. Use care when handling gasoline. Always

stop the engine when refuelling or servicing the fuel

system. Do not smoke or allow open flames or sparks

near gasoline. Do not store motorcycle with gasoline

in the tank, within the home or garage where open

flames, pilot lights, sparks or electric motors are

present. Inadequate safety precautions could cause

an explosion or fire which could result in damage to

property, serious injury.

W A R N I N G

HDO NOT fill the tank to its brim. Please fill fuel

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

to leave air space in the fuel tank to allow for

fuel expansion.

A new motorcycle must be operated according to

the special break-in-procedure. See BREAK-IN-

THE FIRST 300 MILES (500KM) section.

Operate motorcycle only at moderate speeds and

out of traffic until you have become thoroughly

familiar with its operation and handling

characteristics under all conditions.

DO NOT exceed the legal speed limit or drive

too fast for existing conditions. Always reduce

speed when poor driving conditions exist. High

speed increases the influence of any other

condition affecting stability and increases the

possibility of loss of control.

NOTE

7

SAFE OPERATING RULES

W A R N I N G

Avoid overspeeding and never travel over the speed

limit. Excessive speed may cause loss of control and

could result in an accident causing serious injury.

DO NOT exceed 70 MPH (110 km/h) riding solo.

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

a passenger or cargo.

Pay strict attention to road surfaces and wind

conditions. Any two wheeled motorcycle may be

subject to the following upsetting forces :

HWind blasts from passing trucks.

HRough uneven road surfaces.

HSlippery 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 force the handlebar.

Operate your motorcycle defensively. Remember,

a motorcycle does not afford the same protection

as an automobile in an accident. One of the most

common accident situations occurs when the

driver of the other motorcycle fails to see or

recognize a motorcycle and turns into the

oncoming motorcyclist.

Wear an approved helmet, clothing, and foot gear

suited for riding a motorcycle. Bright OR light colors

are best for greater visibility in traffic, especially

at night. Avoid loose, flowing garments and

scarves.

It is not recommended to drive this motorcycle with

pillion seat fitment / pillion rider, Failure to adhere

this may cause damage to motorcycle / rider.

DO NOT allow other 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.

8

SAFE OPERATING RULES

W A R N I N G

Maintain the recommended tyre pressure. Ensure the

front and rear wheels are correctly aligned and the

tyres are seated evenly & properly in the rims. Check

for correct tightness of the spokes in the rims. Inspect

your tyres periodically and replace tyres with approved

tyres only. Failure to do so can lead to improper

balance, abnormal tread wear, poor handling and

could result in serious injury.

W A R N I N G

Royal Enfield recommends replacement of any tyre

punctured or damaged. In some cases small punctures

in the tread area may be repaired from within the

demounted tyre by your Royal Enfield Authorized

Dealer. Speed should not exceed 60 Km/h (40 MPH) for

the first 24 hours after repair and the repaired tyre

should Never be used over 90 Km/h (55 MPH).

In emergency situations, if a temporary repair is

made ride slowly with as light a load as possible

until the tyre is permanently repaired or replaced.

Failure to heed this warning could result in serious

injury.

Safe motorcycle operation requires alert mental

judgement combined with a defensive driving

attitude. D O N OT allow fatigue, alcohol or

drugs to endanger your safety or that of others.

Maintain your motorcycle in proper operating

condition in accordance with the Maintenance

in te r val s ch a r t in t h i s Ow n er’s M anua l .

Particularly important to motorcycle stability is

proper tyre inflation pressure, tread condition.

Pay strict attention to loose and / or broken

spokes, free movement of steering system.

9

SAFE OPERATING RULES

W A R N I N G

DO NOT operate motorcycle with a loose, worn or

damaged steering system, including the front and

rear suspension system. Contact your Royal Enfield

Authorized Dealer for repair of steering or suspension

system. Damaged steering or suspension components

may adversely affect handling which could result in

serious injury.

Regularly inspect rear shockabsorbers and front forks

for any defective suspension can adversely affect

stability and handling which could result in serious injury.

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.

W A R N I N G

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.

W A R N I N G

Exhaust gases contains poisonous carbon monoxide

and chemicals, known to cause Cancer, Birth Defects

or other reproductive defects.

DO NOT INHALE exhaust gases. Never stand close to

the exhaust system of the motorcycle when the engine

is running.

W A R N I N G

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.

10

SAFE OPERATING RULES

W A R N I N G

Consult your Royal Enfield Authorized 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.

W A R N I N G

Use only genuine Royal Enfield replacement fasteners

tightened to the proper torque (See your Royal Enfield Work

Shop Manual). 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.

W A R N I N G

DO NOT exceed the Gross Motorcycle Weight Rating of your

motorcycle. The Gross Motorcycle Weight Rating (GVWR) is

shown on the information plate, located on the frame Down

tube. (GVWR is the sum of the weight of the motorcycle,

accessories, 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.

W A R N I N G

DO NOT tow a disabled motorcycle. The steering and

handling for 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.

W A R N I N G

DO NOT pull a trailer behind a motorcycle. Towing a

trailer may cause reduced braking efficiency, tyre

overloading and unstable handling. Towing a trailer

may cause loss of control of the motorcycle in the front,

leading to an accident resulting in serious injury.

11

RULES OF THE ROAD

Be sure all equipment required by Federal, State,

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.

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 :

HDry

HOily

HIcy

HWet

Watch for loose debris, such as leaves, slippery

substances or loose gravel that can hamper the

stability of your motorcycle.

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.

Keep to the correct side of the road center line

when meeting oncoming motorcycle.

Always sound your horn, actuate your turn signals,

and exercise cau t i on w hen passing other

motorcycles going in the same direction. Never

try to pass another motorcycle going in the same

direction at street intersections, on curves, or when

going up/or down a hill.

At street intersection give the right-of-way to the

motorcycle on your left or right. DO NOT presume

you have the right-of-way.

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 death

or serious injury.

W A R N I N G

12

RULES OF THE ROAD

Always signal when preparing to stop, turn or

pass.

While turning either right or left, watch for

pedestrians, animals, as well as motorcycles.

All traffic signs, including manual controls at

intersections, should be obeyed promptly. SLOW

DOW N at traffic signs near schools and

CAUTION signs at railroad crossings.

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.

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.

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.

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.

13

TECHNICAL SPECIFICATIONS

ENGINE

Engine Type ............

S ingle Cylinder 4 Stroke, Spark

............................... Ignition, Air cooled, Fuel injection

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

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

Swept volume ......... 499cc

Compression ratio . 8.5:1

Max Power ...................

20.3kw @ 5250 rpm

Max Torque ..................

41.3 Nm @ 4000 rpm

Idle RPM ................... 1150+150 RPM

Starting ..................... Kick Start / E-Start

Air filter element .... Paper element

Lubrication .............. Wet sump, Forced lubrication

Engine oil capacity 2.75 litres (First Fill only)

............................ 2.30 to 2.50 litres (subsequent refills)

Engine oil grade .... 15W50 API SL Grade & above,

............................ (JASOMA2)

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

Cooling ..................... Natural air flow

IGNITION SYSTEM

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

Spark plug Electrode gap

0.80 to 0.90 mm

Spark plug .............. WQR8DC (Bosch)

TRANSMISSION

Clutch ........................ Wet multiplate (7 plates)

Primary drive .......... Duplex chain

Primary ratio ........... 2.15 : 1

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

Gear Ratio ............... 1st 3.06:1

............................ 2nd 2.01:1

............................ 3rd 1.52:1

............................ 4th 1.21:1

............................ 5th 1:1

Final drive ............... 17 Teeth (Sprocket)

Final Ratio ................ 2.235:1

Drive Chain links .... 102 links

14

CHASSIS

Frame ....................... Single Down Tube, using

............................ engine as stressed member

Suspension

Front ................... Telescopic, 35mm forks,

............................ 130mm travel

Rear ................... Twin gas charged shock-

............................ absorbers with 5-step adjustable

............................ preload, 80mm travel.

Brakes ...................... Hydraulic Disc Brakes Front

............................ & Rear with ABS System

Front: ................. 280 mm dia disc with twin

............................ piston caliper

Rear: .................. 240 mm dia disc with single

............................ piston & floating caliper

Tyre size

Front ................... 90 / 90 - 19” - 52 P

Rear ................... 110 / 80 - 18” - 58 P

Tyre Pressure

Front ................... 20 psi/1.41 kg/cm2

Rear ................... 30 psi/2.11 kg/cm2

Steering lock ........... In built

Fuel tank capacity . 13.5 litres approx.*

Low fuel warning ... 3.5 litres (approx)

Dead stock of Petrol 0.75 litres (approx)

(unusable fuel)

* The above values are approximate and the actual fuel filling

capacity will vary from the values mentioned.

ELECTRICALS

Generation .............. Alternator (III Phase)

System : E-Start ...... 12V - DC (III Phase)

Battery : E-Start ...... 12V, 12AH MF

Head lamp .............. 12V, H4-60/55W (Halogen)

Position Lamp .......... 12V, 4W

Brake/Tail lamp ..... 12V, P21/5W

TECHNICAL SPECIFICATIONS

15

Parking lamp ...................... 12V, 2W X 2 Nos.

Speedometer lamp ........... 12V, 3.4W

Hi beam indicator ............. 12V,1.7W

Neutral lamp tell tale ......... 12V,1.7W

Turn signal tell tale ............ 12V,1.7W

Turn signal .......................... 12V, R10W X 4 Nos.

Warning Indicator lamps . 12V, 2W X 3 Nos.

Horn ...................................... 12V, 2.5 amp (Max)

Starter Motor ....................... 12V, 0.90 KW

TECHNICAL SPECIFICATIONS

Values / Dimensions given above are for your guidance only.

In view of continuous improvements being done on our products, the specifications are likely to change

without prior notice.

W A R N I N G

Using bulbs / other electrical gadgets other than specified

rating may lead to over loading / erratic behaviour / premature

failure of electrical system.

Modifications on the motorcycle which are not approved by

Royal Enfield may not only disqualify for warranty, but also

affects performance of the motorcycle.

DIMENSIONS

Length ................................ 2100 mm

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

Height ................................. 1160 mm

Wheel base ....................... 1360 mm

Saddle Height ................... 805 mm

WEIGHTS

Kerb weight (90% fuel&oil) 198 Kgs.

Max. Pay load ................... 92 Kgs.

Luggage load carrier .... should not be more

...................................... than 15 Kgs.

16

Capacity 2.75 Ltrs. (First Fill only )

2.30 to 2.50 Ltrs. (during oil & filter

element replacement in periodical

maintenance)

ISO 14 00 1 Op e r at i o n C o ntro l Pr oc ess

As per the guidelines in the ISO 14001 Environmental Management

System, customers are advised to carry out timely replacement of

Engine, Front Fork and Brake oils, ONLY through a Royal Enfield

Authorised Dealer / Service Center for the safe disposal of the

used oils to prevent Environmental pollution.

In case the oils are replaced privately, it is advised to ensure the

old/ removed oils are collected carefully and reached to a certified

disposal agency, nearest to you to safely disposing the oils.

Similarly, hazardous wastes such as old/discarded Batteries, Tyres,

Tubes, Cables, Gaskets, Oil filters etc. should also be disposed off

carefully and properly only through a certified disposal agency.

C A U T I O N

Use of Wrong grade oil will reduce the life of the moving

parts and seriously affect performance.

NOTE

Recommendation subject to change without notice.

DO NOT Mix DOT 4 & other brake fluid together.

Br a ke Flui d

Capacity 60ml

Grade DOT 4

Fr ont Fo rk Oi l

Grade 2W35

Capacity 195 ml/leg

RECOMMENDED LUBRICANTS

En gi ne Oil

Grade 15 W 50 API SL Engine Oil

(JASOMA2)

17

The information given under the titles : Warning, Caution and Note are for your safety and for the

care and safety to your motorcycle and others. Please read these carefully and if disregarded may

result in injury to yourself or others and damages to the motorcycle.

SAFETY DEFINITIONS

Indicates important and useful messages for clearer understanding.

All Images shown in subsequent pages are for reference to explain and need not to be exactly the

same on the model you own.

NOTE

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

C AU T I O N

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

or other persons.

W A R N I N G

18

MOTORCYCLE IDENTIFICATION NUMBERS

FRAME NUMBER

Punched on steering head tube right side.

ENGINE NUMBER

Punched on crankcase left top side.

19

LOCATION OF KEY PARTS

1. Horn Button

2. Turn Signal Switch

3. Cluth Lever

4. Day Flash

5. Head Lamp Dip Switch

6. Ignition Switch

7. Speedo Meter

8. Warning Indicator

9. Engine Kill Switch

10. Brake Lever

11. E-Start Switch Button

12. Petrol Tank Cap

13. Rear View Mirrors

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6

3

5

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78910

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