Owner's Manual - 2004 Royal Enfield Bullet 500 Cast Iron Engine

Introduction

Congratulations on owning a 2004 Royal Enfield Bullet 500 Cast Iron Engine! This manual provides essential information on maintenance, operating procedures, and safety guidelines to ensure optimal performance and longevity of your motorcycle.

1. Technical Specifications

Engine

• Type: 499cc, single-cylinder, 4-stroke, air-cooled
• Power Output: 22 BHP @ 5400 RPM
• Torque: 40.85 Nm @ 3000 RPM
• Compression Ratio: 6.5:1
• Ignition: Contact breaker (CB) Points / CDI (varies by model)
• Fuel System: 28mm Mikuni VM carburetor
• Lubrication: Wet sump with external oil lines
• Valve Timing: OHV (Overhead Valve) with pushrod actuation

Transmission

• Type: 4-speed / 5-speed constant mesh
• Clutch: Wet, multi-plate
• Final Drive: Chain

Chassis & Suspension

• Frame: Single downtube, steel tubular
• Front Suspension: Telescopic fork, hydraulic damping
• Rear Suspension: Twin shock absorbers with 5-step preload adjustment

Brakes & Wheels

• Front Brake: 7-inch drum brake
• Rear Brake: 6-inch drum brake
• Front Wheel: 19-inch spoke wheel
• Rear Wheel: 19-inch spoke wheel

Electrical System

• Battery: 12V, 14Ah (DC System)
• Headlight: 35W / 35W Halogen
• Charging Output: 13.5V - 14.5V @ 3000 RPM
• Spark Plug: NGK B8ES (gap: 0.7 - 0.8mm)

2. Controls & Instrumentation

Handlebar Controls

• Clutch Lever: Left side, disengages clutch for gear shifts.
• Front Brake Lever: Right side, activates front drum brake.
• Throttle: Right side, twist to accelerate.
• Kill Switch: (if equipped) Cuts engine power.
• Horn Button: Located on the left switch cluster.

Foot Controls

• Gear Shifter: Left side, 1 down, 3 up (4-speed) / 1 down, 4 up (5-speed).
• Rear Brake Pedal: Right side, engages the rear drum brake.

Instrument Panel

• Speedometer: Displays speed in km/h or mph.
• Odometer: Tracks total distance covered.
• Ammeter: Indicates battery charging and discharge.
• Ignition Switch: Powers the electrical system.

3. Starting & Stopping Procedure

A. Starting the Engine

Electric Start Variant:

1. Ensure the gear is in neutral.
2. Turn the ignition key ON.
3. Pull in the clutch lever.
4. Press the electric starter button.

Kick Start Variant:

1. Ensure the fuel tap is ON.
2. Turn the ignition key ON.
3. Depress the decompression lever and kick the starter gently.
4. Bring the piston to the compression stroke (indicated by ammeter returning to center).
5. Give a strong kick on the starter lever.
6. Do not use throttle while kicking.

B. Stopping the Engine

1. Reduce throttle and shift to neutral.
2. Turn the ignition key OFF.
3. Turn fuel tap to OFF position (to prevent leaks).
4. Place the motorcycle on the center stand.

4. Running-In Period (First 2000 km)

Proper break-in ensures longevity:

• 0-500 km: Keep speeds below 50 km/h, avoid full throttle.
• 500-1000 km: Gradually increase speed but avoid prolonged high RPM.
• 1000-2000 km: Ride normally but avoid aggressive acceleration.
• First oil change at 500 km, followed by another at 1500 km.

5. Maintenance Schedule

6. Essential Maintenance Procedures

A. Engine Oil Change

• Use 20W-50 API SL grade oil (approx. 2.25L).
• Drain using 17mm drain bolt at the bottom of the engine.
• Refill and check level with the dipstick.

B. Chain Lubrication & Adjustment

• Maintain 20-25mm slack.
• Use SAE 90 gear oil or spray-type chain lube.

C. Carburetor Tuning

• Adjust idle speed screw to maintain 1000-1100 RPM.
• Adjust air-fuel mixture screw for smooth acceleration.

D. Spark Plug Replacement

• Use NGK B8ES, set gap to 0.7-0.8mm.
• Check condition every 3000 km, replace every 6000 km.

7. Common Issues & Troubleshooting

8. Storage & Seasonal Care

• Short-Term Storage: Keep fuel tap OFF, park on center stand.
• Long-Term Storage: Drain fuel tank, disconnect battery, lubricate moving parts.

9. Safety Precautions

• Always wear a helmet and protective gear.
• Check brakes, lights, and tire pressure before every ride.
• Avoid overloading beyond the recommended capacity.
• Do not rev hard on a cold engine.
• Always use genuine parts for repairs and maintenance.

10. Conclusion

The 2004 Royal Enfield Bullet 500 Cast Iron Engine is a classic machine built for durability and smooth cruising. Regular maintenance and proper handling will ensure a long and trouble-free ownership experience. Ride responsibly and enjoy the timeless charm of your Bullet 500!

🏍️ Keep Riding, Keep Thumping!