Royal Enfield · Royal Enfield Bullet, iron barrel (Redditch 1949-1962, Madras 1955-2008)

Bullet 350 / 500 (Madras / Chennai)

Library entry covers 1955-2008

25 factory 47 guideline

Published source

Royal Enfield Bullet 500 Owner's Manual (Royal Enfield), Periodical Maintenance pp.40-42

Factory owner's handbook. Covers Bullet 500 owner's manual (Royal Enfield, Chennai), periodical maintenance chart in km and months.

Open the source

72 items for a 1955 model, grouped by interval the way a factory chart is laid out.

How this bike is built (what the schedule is based on)

Engine cycle: Four-stroke
Engine lubrication: Wet sump (oil in crankcase)
Oil filtration: Mesh screens / strainers only
Valve gear: Overhead valve, pushrods, adjustable tappets
Ignition: Battery and coil with contact points
Charging: Alternator / stator with rectifier
Battery: Wet cell (flooded lead-acid, needs topping up)
Fuel system: Single carburetor
Cooling: Air / oil cooled
Primary drive: Chain in oil-bath case with its own oil
Gearbox oil: Separate gearbox oil
Clutch control: Hand lever, cable
Final drive: Chain
Front suspension: Telescopic fork
Rear suspension: Swingarm, twin shocks
Front brake: Drum (or band / stirrup)
Rear brake: Drum (or band / belt rim)
Wheels: Spoked, tubed
Sidecar: No sidecar

Maintenance schedule

1955 Royal Enfield Bullet 350 / 500 (Madras / Chennai)

On the road: every 200 mi

1 item

Check engine oil level

Pre-ride / on the road

Guideline

Each fuel stop on old machines. Dry sump: check the tank hot, engine idling or just stopped, per your manual.

On the road: every 300 mi

2 items

Check lights, horn, brake light switches

Pre-ride / on the road

Guideline
Check tire pressures

Pre-ride / on the road

Guideline

On the road: every 500 mi

1 item

Walk-around: check nuts and bolts for vibration loosening

Pre-ride / on the road

Guideline

Old machines shake things loose: exhaust nuts, mudguard stays, footrests, tank mounts, battery strap.

On the road: every 600 mi

1 item

Check chain slack and rear wheel alignment

Pre-ride / on the road

Factory

Manual: Rear drive chain: adjust. Factory: Periodical maintenance pp.40-42: every 1,000 km; rear brake pedal free play at the same interval

On the road: every 1,000 mi

1 item

Check road kit: plugs, points file, master link, tube patches, wire, tape

Pre-ride / on the road

Guideline

On the road: every 1,900 mi or 3 months

1 item

Lubricate drive chain

Pre-ride / on the road

Factory

Manual: Rear drive chain: clean and lubricate. Factory: Periodical maintenance pp.40-42

Every 600 mi

1 item

Adjust clutch free play, lubricate cable and lever pivot

Primary and gearbox

Factory

Manual: Clutch lever free play: check and adjust. Factory: Periodical maintenance pp.40-42: hand levers and kick starter pivot lubricated every 1,000 km

Every 1,000 mi or 1 month

1 item

Check battery electrolyte, top up with distilled water

Ignition and electrics

Guideline

Wet-cell batteries on old machines need regular topping up, more in hot weather.

Every 1,000 mi or 6 months

4 items

Check gearbox oil level

Primary and gearbox

Guideline
Grease swingarm pivot

Rear suspension and frame

Guideline
Adjust front drum brake

Brakes

Guideline
Adjust rear drum brake and rod / cable linkage

Brakes

Guideline

Every 1,500 mi or 6 months

1 item

Clean drive chain thoroughly (remove and soak, re-lube)

Final drive

Guideline

Non O-ring chains on old machines: remove, clean, soak in hot chain grease or lube, refit with the master link clip closed end leading.

Every 1,900 mi or 3 months

7 items

Inspect, clean and gap spark plugs

Engine

Factory

Manual: Spark plugs (2): clean and adjust. Factory: Periodical maintenance pp.40-42
Check throttle cable(s) free play and return

Fuel and air

Factory

Manual: Accelerator and carburetor cable play: adjust. Factory: Periodical maintenance pp.40-42: carburetor (CV type) cleaned and tuned by the dealer
Clean / inspect air filter

Fuel and air

Factory

Manual: Air filter paper element: clean. Factory: Periodical maintenance pp.40-42
Clean battery terminals, check charge and strap

Ignition and electrics

Factory

Manual: Battery terminals: clean, apply petroleum jelly. Factory: Periodical maintenance pp.40-42: electrolyte level inspected every 3,000 km
Check steering head bearing adjustment

Front end

Factory

Manual: Steering ball races: adjust play, lubricate. Factory: Periodical maintenance pp.40-42: lubricate every 6,000 km; races replaced every 12,000 km
Inspect tire tread, sidewalls and date codes

Wheels and tires

Factory

Manual: Tire wear (front and rear): inspect. Factory: Periodical maintenance pp.40-42
Lubricate control cables and lever pivots

Controls and cables

Factory

Manual: Rear brake cam, brake pedal pivot, stand and footrest pivots: lubricate. Factory: Periodical maintenance pp.40-42: rear brake cam every 6,000 km

Every 2,000 mi or 12 months

2 items

Change primary chaincase oil

Primary and gearbox

Guideline
Check / adjust primary chain

Primary and gearbox

Guideline

Every 3,000 mi or 12 months

12 items

Check engine mounting bolts and plates

Engine

Guideline
Check / set ignition timing

Ignition and electrics

Guideline
Clean and gap contact breaker points, oil cam felt

Ignition and electrics

Guideline
Adjust clutch pushrod / clutch adjuster

Primary and gearbox

Guideline
Change gearbox oil

Primary and gearbox

Guideline
Check chain guard, chain oiler (if fitted), rear chain case

Final drive

Guideline
Inspect chain and sprockets for wear (measure stretch)

Final drive

Guideline
Check steering damper (friction or hydraulic)

Front end

Guideline
Inspect fork seals, stanchions and fork boots

Front end

Guideline
Check footrests, pegs, rear brake and gear lever pivots

Rear suspension and frame

Guideline
Grease and check center / side stand and springs

Rear suspension and frame

Guideline
Check wheel bearings for play

Wheels and tires

Guideline

Every 3,700 mi or 6 months

7 items

Change engine oil

Engine

Factory

Manual: Engine oil: replace. Factory: Periodical maintenance pp.40-42: first at 500 km; check level every 1,000 km
Check engine breather and oil return

Engine

Factory

Manual: PAV (pulse air) pipes and hose clips: clean. Factory: Periodical maintenance pp.40-42: inspect every 3,000 km
Clean oil strainers / mesh screens

Engine

Factory

Manual: Sump filter (oil strainer) and magnetic drain plugs: clean. Factory: Periodical maintenance pp.40-42: first at 500 km and 3,000 km
Replace oil filter

Engine

Factory

Manual: Engine oil filter element: replace. Factory: Periodical maintenance pp.40-42: first at 500 km; cleaned at 3,000 km
Clean fuel tap filter / sediment bowl

Fuel and air

Factory

Manual: Fuel tap and filter, fuel tank: clean. Factory: Periodical maintenance pp.40-42
Check swingarm bushes for play

Rear suspension and frame

Factory

Manual: Swing arm pivot bush and spacer: lubricate. Factory: Periodical maintenance pp.40-42: replace at 24,000 km; rear wheel cush rubbers inspected and replaced every 12,000 km
Check spoke tension and wheel true

Wheels and tires

Factory

Manual: Spoke tightness and wheel rim run-out: inspect. Factory: Periodical maintenance pp.40-42

Every 4,000 mi or 12 months

1 item

Lubricate brake cam spindles, check linings and drums

Brakes

Guideline

Every 5,000 mi or 2 years

1 item

Check cylinder head bolt torque

Engine

Guideline

Air-cooled iron and alloy engines can lose head bolt tension; follow your manual's sequence and whether it is done hot or cold.

Every 6,000 mi or 12 months

4 items

Clean carburetor float bowl(s), check float level and jets

Fuel and air

Guideline

Ethanol fuel varnishes old carbs quickly in storage.
Check charging voltage and regulator / cut-out

Ignition and electrics

Guideline
Inspect rear shocks for leaks and damping

Rear suspension and frame

Guideline
Lubricate speedometer / tachometer cables, check drive

Controls and cables

Guideline

A dry speedo cable whips the needle and eventually kills the instrument.

Every 6,000 mi or 2 years

2 items

Lubricate and check automatic advance unit

Ignition and electrics

Guideline
Repack / replace wheel bearings

Wheels and tires

Guideline

Cup-and-cone and taper roller hubs need periodic repacking and adjustment.

Every 7,500 mi

5 items

Inspect coolant hoses and clamps

Engine

Factory

Manual: Rubber hoses, air filter to carburetor and adaptor: replace. Factory: Periodical maintenance pp.40-42: inspect every 3,000 km
Replace air filter element

Fuel and air

Factory

Manual: Air filter paper element: replace. Factory: Periodical maintenance pp.40-42
Replace fuel lines

Fuel and air

Factory

Manual: Fuel hose and pipe: replace. Factory: Periodical maintenance pp.40-42: inspect every 3,000 km; HT leads inspected every 3,000 km
Change fork oil

Front end

Factory

Manual: Front fork oil: replace. Factory: Periodical maintenance pp.40-42: first at 9,000 km; inspect for leaks between
Replace brake fluid

Brakes

Factory

Manual: Brake fluid (disc brake): replace. Factory: Periodical maintenance pp.40-42: inspect every 3,000 km

Every 9,300 mi

2 items

Check and adjust valve clearances

Engine

Factory

Manual: Inlet and exhaust valve seating: inspect. Factory: Periodical maintenance pp.40-42: dealer item
Replace spark plugs

Engine

Factory

Manual: Spark plugs (2): replace. Factory: Periodical maintenance pp.40-42

Every 10,000 mi or 2 years

1 item

Compression test (or leak-down)

Engine

Guideline

Every 10,000 mi or 3 years

1 item

Repack / replace steering head bearings

Front end

Guideline

Many old machines use loose balls in cups and cones. Taper roller conversions are common.

Every 10,000 mi

1 item

Replace chain and sprockets (wear based)

Final drive

Guideline

Every 12,000 mi or 3 years

1 item

Replace points and condenser

Ignition and electrics

Guideline

Every 15,000 mi or 5 years

1 item

Inspect clutch plates and springs

Primary and gearbox

Guideline

Every 15,000 mi

1 item

Replace brake linings / skim drums (wear based)

Brakes

Guideline

Every 18,600 mi

1 item

Decarbonize head, grind / lap valves (top-end decoke)

Engine

Factory

Manual: Cylinder head and exhaust: decarbonize. Factory: Periodical maintenance pp.40-42: dealer item

Every 25,000 mi or 6 years

1 item

Replace swingarm bushes / bearings

Rear suspension and frame

Guideline

Every 30,000 mi or 6 years

1 item

Rebuild forks: seals, bushes, springs

Front end

Guideline

Every 12 months

1 item

Check speedometer / odometer against a known distance

Controls and cables

Guideline

Old speedos drift with tire size and drive wear. Use phone GPS over a measured 10 miles / km.

Every 2 years

3 items

Inspect fuel tank for rust, sealer failure, leaks

Fuel and air

Guideline
Inspect wiring, bullet connectors and ground points

Ignition and electrics

Guideline
Inspect frame, welds and lugs for cracks

Rear suspension and frame

Guideline

Every 6 years

2 items

Replace inner tubes and rim tape with tires

Wheels and tires

Guideline
Replace tires on age (regardless of tread)

Wheels and tires

Guideline

Guideline lines: Intervals here are general guidelines for the machine's era and layout, compiled for this app. They are not factory manual figures. Check your workshop manual, and edit any interval in the bike's Schedule tab.

Keep up with this schedule on your phone

Add the bike in the app and this chart loads itself, ready to log against and edit.

Coming soon to Google Play

Other 1955 Royal Enfield models

All 1955 Royal Enfield

Meteor / Super Meteor / Constellation / Interceptor 700-750

Guideline