MotoService Log
Royal Enfield Bullet 350 / 500 (Madras / Chennai)
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Royal Enfield · British pre-unit single, telescopic fork (1946-1966)

Bullet 350 / 500 (Madras / Chennai)

Library entry covers 1955-2008

44 factory 37 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.

81 items for a 1994 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
Dry sump (separate oil tank)
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

1994 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 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 1,900 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 621 mi

3 items
  • Engine Oil: Check level at every 1000 Kms or earlier as required
    Engine
    Factory

    Factory: As printed: Check level at every 1000 Kms or earlier as required

  • Rear brake pedal free play: Adjust every 1000 Kms or earlier as required
    Brakes
    Factory

    Factory: As printed: Adjust every 1000 Kms or earlier as required

  • Hand levers & kick starter lever pivot: Lubricate every 1000 Kms or earlier as required
    Controls and cables
    Factory

    Factory: As printed: Lubricate every 1000 Kms or earlier as required

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

2 items
  • Adjust front drum brake
    Brakes
    Guideline
  • Adjust rear drum brake and rod / cable linkage
    Brakes
    Guideline

Every 1,864 mi or 3 months

6 items
  • HT leads for crack: I
    Engine
    Factory

    Factory: As printed: I marked at every column: 0.5 (1.5 months), 3 (3), 6 (6), 9 (9), 12, 15, 18, 21, 24, 27, 30 Kms (x 1000)

  • Rubber hose, Adaptor: I
    Engine
    Factory

    Factory: As printed: I at every column except R at 12 and 24 Kms (x 1000)

  • Fuel hose / pipe: I
    Fuel and air
    Factory

    Factory: As printed: I at every column except R at 9 and 21 Kms (x 1000)

  • Rubber hose, Air filter to Carburetor: I
    Fuel and air
    Factory

    Factory: As printed: I at every column except R at 12 and 24 Kms (x 1000)

  • Battery Electrolyte level: I
    Ignition and electrics
    Factory

    Factory: As printed: I marked at every column: 0.5 (1.5 months), 3 (3), 6 (6), 9 (9), 12, 15, 18, 21, 24, 27, 30 Kms (x 1000)

  • Brake fluid (Disc brake): I
    Brakes
    Factory

    Factory: As printed: I at every column except R at 12 and 24 Kms (x 1000)

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 3,000 mi or 12 months

8 items
  • Check / set ignition timing
    Ignition and electrics
    Guideline
  • Clean and gap contact breaker points, oil cam felt
    Ignition and electrics
    Guideline
  • 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.

  • Inspect chain and sprockets for wear (measure stretch)
    Final drive
    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 3,728 mi

2 items
  • Engine Oil: I
    Engine
    Factory

    Factory: Printed per the re-read doubt: the Engine Oil row alternates R and I (R at 0.5, 6, 12...; I at 3, 9, 15... Kms x 1000); the I marks are spaced every 6,000 km starting at 3,000 km, taken as inspect every 6,000 km. Months not set because the months row only runs to 9. The existing entry holds the replace. (From the re-read doubt notes: Royal Enfield Bullet 350 / 500 (Madras / Chennai), printed line or second operation stated in the DOUBT line.)

  • PAV pipes & hose clip: I
    Engine
    Factory

    Factory: As printed: I at 0.5, 3, 9, 15, 21, 27 Kms (x 1000) (C at 6, 12, 18, 24, 30)

Every 4,000 mi or 12 months

1 item
  • Lubricate brake cam spindles, check linings and drums
    Brakes
    Guideline

Every 5,000 mi or 12 months

2 items
  • Change primary chaincase oil
    Primary and gearbox
    Guideline
  • Check / adjust primary chain
    Primary and gearbox
    Guideline

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
  • Change gearbox oil
    Primary and gearbox
    Guideline

Every 7,456 mi

3 items
  • Front Fork oil / leak: I
    Front end
    Factory

    Factory: As printed: I at 3, 15, 27 Kms (x 1000) (R at 9 and 21)

  • Steering ball races / play adjustment: R
    Front end
    Factory

    Factory: As printed: R at 12 and 24 Kms (x 1000) (A at 3, 9, 15, 21, 27; L at 6, 18, 30)

  • Rear wheel cush rubbers: I&R
    Wheels and tires
    Factory

    Factory: As printed: I&R at 12 and 24 Kms (x 1000)

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 12,000 mi or 2 years

1 item
  • Grease swingarm pivot
    Rear suspension and frame
    Guideline

Every 12,000 mi or 3 years

1 item
  • Replace points and condenser
    Ignition and electrics
    Guideline

Every 14,913 mi

1 item
  • Swing Arm pivot bush & spacer: R
    Rear suspension and frame
    Factory

    Factory: As printed: R at 24 Kms (x 1000) only (L at 6, 12, 18, 30)

Every 15,000 mi

1 item
  • Replace brake linings / skim drums (wear based)
    Brakes
    Guideline

Every 16,777 mi

1 item
  • Tire wear (Front & Rear): R
    Wheels and tires
    Factory

    Factory: As printed: R at 27 Kms (x 1000) only (I at 6, 9, 12, 15, 18, 21, 24, 30)

Every 18,000 mi

1 item
  • Replace chain and sprockets (wear based)
    Final drive
    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 20,000 mi or 4 years

2 items
  • Repack / replace steering head bearings
    Front end
    Guideline

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

  • Repack / replace wheel bearings
    Wheels and tires
    Guideline

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

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

2 items
  • 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

No interval set

3 items
  • Engine oil filter element: C
    Engine
    Factory

    Factory: As printed: C at 3 Kms (x 1000) / 3 months only (R at 0.5, 6, 12, 18, 24, 30)

  • Carburetor (C.V. Type): *Clean, Inspect and Tune
    Fuel and air
    Factory

    Factory: As printed: *Clean, Inspect and Tune (spans all columns, no interval); * Refer Service Manual

  • Earth wire eyelet (behind battery carrier): I
    Ignition and electrics
    Factory

    Factory: As printed: I at 12 and 30 Kms (x 1000) only

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.

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Other 1994 Royal Enfield models

All 1994 Royal Enfield
1991-2019
Bullet 500
Guideline