Royal Enfield Thunderbird 500 User manual

FOREWORD

We congratulate you on your choice of the legendar y Royal Enfield motorcycle and welcome you to the

exciting world of motorcycling. The Thunderbird 500, the ultimate highway cruiser now comes with a solid

500cc engine, a bigger 20 litre tank, ergonomic seating and a powerful projector headlamp. This manual

will help you to operate your motorcycle the right way and guide you to maintain it meticulously. We have

also provided tips on safe riding and on minor adjustments for the care of your motorcycle. Please avail the

four free & three paid services at the nearest Authorised Service Center, at the appropriate time to maintain

your motorcycle in top riding condition. Log on to the exciting world of Royal Enfield on www.royalenfield.com

to get to know more about the company, its products and exciting news from time to time. We request you to

carefully read the terms and conditions of warranty and other useful information given in this manual

before starting to use your Thunderbird 500.

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. 594069/B / Qty. 500 / Nov. ‘16

NOT E : BS II I

T h i s m o t o r cy c l e m e et s E m i s s io n N o r m s -

B h ar a t ( Tr e m ) S ta g e - I I I

D i s c l a i m e r

Following precautions are to be taken, to ensure longer

paint life of your motorcycle.

1. Do not polish your motorcycle as it increases gloss.

2. Wash only with plain water.

3. Scratches or marks cannot be removed or touched up.

Applicable for Stone Black Colour / Matt Paint Finish

NOTE: Warranty is not applicable for Stone Black Colour /

Matt paint finish due to uniqueness of the paint.

C o n ta c t U s :

Royal Enfield Support : 1800-2100-007

Email : support@royalenfield.com

Twitter : @RoyalEnfieldSupport

Web : www.royalenfield.com

CONTENTS

Personal and Motorcycle Information 4

Technical Specifications 5

Recommended Lubricants 8

Safety Definitions 9

Motorcycle Identification Numbers 10

Location of Key Parts 11

Operation of Controls 14

Pre-Operational Checks 21

Safe & Happy Riding 22

Running in Period 23

Starting 24

Gear Shifting, Riding & Stopping 25

Parking 26

Periodical Maintenance Chart 27

Tools & First Aid kit 30

Minor Maintenance Tips 31

Long Trip Precautions 43

Washing Procedure 44

Storage Precautions 45

Trouble Shooting 46

Warranty Terms & Conditions 47

Emission Warranty 49

Service Coupons 52

Paid Service & Maintenance Record 67

Regional & Area Offices 69

Authorised Dealer Address 70

Notes 88

A n n e x u r e s

Motorcycle Installation Form

Pre-Delivery Inspection Report

Motorcycle Installation Confirmation By Customer

Form 22

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

Motorcycle Installation Form (MIF) No.

ENGINE

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

Single Cylinder 4 Stroke, Air cooled

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

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

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

Compression ratio . 8.5:1

Max Power BHP @ RPM

27.2@5250

Max Torque in NM@ RPM

41.3@4000

Idle RPM .................... 1050+200

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 .... Royal Enfield 15W50 API SL (JASOMA)

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

IGNITION SYSTEM

Ignition system ........ Electronic Ignition ECU / Variable

Spark plug Electrode gap

0.70 to 0.80 mm

Spark plug ............... WR8DP M14 (Bosch) &

............................. UR6DC M10 (Bosch)

TRANSM ISSION

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 ................ 18 Teeth (F.D. Sprocket)

Final Ratio ................. 2.11:1

Drive Chain links .... 102 links

CHASSIS

Frame......................... Single Down Tube, Using

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

Suspension

Front ....................

Inline Telescopic Fork (dia 41mm)

................................. hydraulic damping stroke 130mm

Rear ....................

Rigid oval section swing arm with

................................. gas filled shockabsorbers stroke

................................. 80mm (5 steps adjustable)

Brakes

Front Disc ........... 280mm ventilated disc,

............................. Double piston caliper

Rear Disc ........... 240mm ventilated disc,

............................. Single piston caliper

Tyre size

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

Rear .................... 120 / 80 - 18” - 62 P

Tyre Pressure

Solo

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

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

With Pillion

Front .................... 22 psi/1.55 kg/cm2

Rear .................... 32 psi/2.25 kg/cm2

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

Fuel tank capacity .. 19 litres approx. *

Low fuel warning ... Last bar blink system

............................. 5.5+0.50 litres approx.

Dead stock of Petrol 0.5 litre approx.

(unusable fuel)

* The above values are approximate and the actual fuel filling

capacity will vary from the values mentioned.

ELECTRICALS

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

System : E-Start ....... 12V - DC

Battery : E-Start ...... 12V - 14 AH MF

DIMENSIONS

Length .................................. 2060 mm

Width ..................................... 790 mm

Height ................................... 1205 mm

Wheel base ......................... 1350 mm

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

Saddle Height .................... 775 mm

WEIGHTS

Kerb weight (90% fuel&oil) 195 Kgs.

Max. Pay load ..................... 170 Kgs.

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.

Head lamp .............. Projection type, H7 bulb 55/55W

............................. with LED light guide ring

Position indicator .... LED, 12V X 1 No.

Brake/Tail lamp .....

LED lamp with position light guides

Hi beam indicator . LED, 12V X 1 No.

Neutral indicator ..... 12V-1.4W X 1 No.

Turn signal indicator LED, 12V X 2 Nos.

Turn signal / ............. 12V, 10W X 4 Nos.

hazard warning

Horn ............................ 12V, 2.5 Amp (Max.) X 2 Nos.

Starter Motor ........... 12V, 900 Watts

Instrument Cluster .. Digital cluster with LCD panel

Hazard indicator ... LED, 12V X 1 No.

Side stand indicator 12V-1.4W X 1 No.

Malfunction ............... LED, 12V X 1 No.

Indicator Lamp (MIL)

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.

Capacity 2.75 Ltrs. (First Fill only )

2.30 to 2.50 Ltrs. (during oil & filter

element replacement in periodical

maintenance)

I SO 1 4 00 1 O pe r at io n C o nt ro l P r oc es s

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.

RECOMMENDED LUBRICANTS

E ng i n e O i l

Grade Royal Enfield 15 W 50 API SL

Engine Oil

(JASO MA)

DO NOT Mix DOT 3 & DOT 4 brake fluid together.

Front Fo r k Oil

Grade Royal Enfield Front

Fork Oil (or

Gabriel Fork Oil

2w 35)

Capacity 430+3 ml/leg

B r a ke F l u i d

Capacity Fr. 60 ml

Rr. 100 ml

Grade

DOT 3 or

DOT 4

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.

W A R N I N G

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

or other perso ns.

C AU T I O N

This message if disr egarded m ay result in damage to the motorcycle.

NOTE

Indicates i mportant and useful mes sages f or cl earer understand ing.

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

same on the model you own.

SAFETY DEFINITIONS

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