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Royal Enfield Bullet 612cc project

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struan80
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PostPosted: 23:04 - 18 Aug 2021    Post subject: Reply with quote

It's good putting a face to a name. Smile
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stinkwheel
Bovine Proctologist



Joined: 12 Jul 2004
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PostPosted: 21:07 - 25 Aug 2021    Post subject: Reply with quote

Put another 600 miles on the bike at the weekend. Protracted A-road/motorway section and some twisties in the Scottish Highlands complete with luggage. including a 7 hour run back down from Royal Deeside.

The rack held up well, I think I'll put one cross piece and a couple of leather straps on. I'll als re-infirce the two flatbar pieces to stop them flexing side to side. I think I might just put a bit of a lengthwise curve in them which should make them much more rigid.

The bike will happily sit at 65/70 on everything but a steep hill, it never dropped below 60mpg.

I've pulled the top end off with a view to both having a look and to removing one of the compression plates.

This is as clean a burn as I've seen on a Bullet piston, pretty happy with it. The mark on the crown is where the dead-stop tool marked the carbon deposit them I picked at it with an oily finger. It's a bit on the lean side I think. I'll try upping the main jet.

https://lh3.googleusercontent.com/pw/AM-JKLW2wGmbNiaoIBhbHC6-brHynfS_G9hTyNRaZ-TsBZANaNO80VK5W6u4hO5SZfUkwVUy-K5KCAleW1ukpvU-otaEbuRB8U1rhI47ZDUzA3cha_YW1f3tbXlpVSuEFjZFkmg2Q58pGLvDp5gHbNcY8Q1E=w1576-h886-no

Again, as little blowpast as i've seen on an enfield. It would be terrible on a Jap bike but there's a hell fo a lot of oil hanging about in this motor (no valve stem seals etc). I think a "hard" run-in was the way to go.
https://lh3.googleusercontent.com/pw/AM-JKLWqKH-ykArXEfYLUrg7paQ5iEBRZdz2Wk7Rl-kp-rMKPlm_B6e1FfgK1oQOHa6X1jWO7ONx172r1d1xGRS1P376HWmMB8-WZyRjuAlVZgIOf2R5oKBJEC_MWnIBzR79QCViO68_Fvw3Tw1ThhIBnrE0=w1576-h886-no

I've calculated the compression ratios and if I remove the 2mm plate and leave the 3mm one in, it should make 10.6:1 compression. If I use the 2mm plate by itself it would be 11.6:1 which is a bit on the steep side for road use and road fuel.

Job for the weekend is to reassemble with blu-tak on the piston crown to check the valve to piston clearance is acceptable with the 3mm plate then assemble with new gaskets. I've managed to get hold of a composite gasket with a proper fire ring in place of the copper one it currently has.

Turns out the adjuster on the exhaust pushrod was also slightyl bent but this didn't cause an issue with clearances because it has a "cup" on both ends. Easily replaced, I have a spare from the previous bent rod. It's no longer backfiring on startup so hopefully that issue is past.

Couple of other housekeeping jobs to do including making an alloy deflector plate to stop the breather output flinging up off the chain and all over the bike. Also to re-fit a shorter rear brake arm to stop it camming-on.

I have some diferent capacitors to try on it to see if they'll store a bit more power, if not, I may go back to battery. It should fit int he "spare" toolbox.

The plan is to go touring in the Spanish Picos on it at the end of September. It's shown it can do it now and I'll hopefully have a bit more poke to get up to a cruising speed of 70 and a little in the back pocket for overtakes. If I want to have a higher cruising speed, I'd have to start messing with the primary gearing because the transmission sprockets are as tall as they'll go.
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.
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stinkwheel
Bovine Proctologist



Joined: 12 Jul 2004
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PostPosted: 18:18 - 27 Aug 2021    Post subject: Reply with quote

Checked valve to piston clearance by means of applying blu-tak to the piston, re-assembling and turning the engine over then measuring the squished bit.

5.5mm. Which is a country mile. Minimum is 1.3mm. This engine would be safe from dinging a valve even with negative deck height. Which is reassuring.
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.
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virus
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Joined: 17 Aug 2006
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PostPosted: 18:39 - 27 Aug 2021    Post subject: Reply with quote

stinkwheel wrote:
Checked valve to piston clearance by means of applying blu-tak to the piston, re-assembling and turning the engine over then measuring the squished bit.

5.5mm. Which is a country mile. Minimum is 1.3mm. This engine would be safe from dinging a valve even with negative deck height. Which is reassuring.


So your taking both compression plates out, throwing the main jet away and running it on methanol right? Cool Laughing
____________________
own: 81 xs1100g...
owned: 85 rat CG (sold), 91 GS500e (stolen), 84 gsx400f (scrapped), 81 z250 (siezed, siezed, scrapped), 83 cb250rs (sold), 84 gpz750r ratfighter (killed) 84gpz400 (sold), '80 cb650 ratfighter (wrote off) 95gsx6/12f ratfighter (killed) 91 xj900 (sold)
stinkwheel Well I just had my hands up a pigs fanny. Which makes your concerns pale into insignificance.
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stinkwheel
Bovine Proctologist



Joined: 12 Jul 2004
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PostPosted: 22:13 - 27 Aug 2021    Post subject: Reply with quote

virus wrote:


So your taking both compression plates out, throwing the main jet away and running it on methanol right? Cool Laughing


Well. If E85 becomes readily available at filling stations...
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.
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bladerunner
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Joined: 09 Sep 2006
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PostPosted: 23:15 - 04 Sep 2021    Post subject: Reply with quote

Nice to know its working well and doing its thing! I've done a few hundred miles on a borrowed Derv bullet this year and it's way off my usual litre size jap sports bikes or small 80's/90's 2 strokes......however I must admit it's been ace fun in its quirky kinda way and I'm envious of your extra HP.....I think torque wise I may have you beat, but handling wise I'm actually rather impressed with the old Bullet for what it is!! I'm managing just over 200 mpg so given the long range tank John O groats to land end is doable with 50 miles or so left in the tank Shocked Laughing Laughing Wouldnt actually know for sure tho as it last got fuelled in 2018 and has only covered 1000Km so far and I'll leave it another couple of hundred more before I top up again!!
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Current bikes...cbr929, KDX200's, Rd125lc mk2, RGV250's
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stinkwheel
Bovine Proctologist



Joined: 12 Jul 2004
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PostPosted: 22:03 - 05 Sep 2021    Post subject: Reply with quote

bladerunner wrote:
Nice to know its working well and doing its thing! I've done a few hundred miles on a borrowed Derv bullet this year and it's way off my usual litre size jap sports bikes or small 80's/90's 2 strokes......however I must admit it's been ace fun in its quirky kinda way and I'm envious of your extra HP.....I think torque wise I may have you beat, but handling wise I'm actually rather impressed with the old Bullet for what it is!! I'm managing just over 200 mpg so given the long range tank John O groats to land end is doable with 50 miles or so left in the tank Shocked Laughing Laughing Wouldnt actually know for sure tho as it last got fuelled in 2018 and has only covered 1000Km so far and I'll leave it another couple of hundred more before I top up again!!


I'm pretty sure you need to do an oil change when you top up the tank on those? Laughing
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.
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Old Thread Alert!

There is a gap of 1 year, 67 days between these two posts...

stinkwheel
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Joined: 12 Jul 2004
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PostPosted: 13:56 - 12 Nov 2022    Post subject: Reply with quote

Been quite some time since I updated this. It's been eventful!

The Picos trip in 2021 was a qualified success. Qualified in that the engine seized about 20 miles out of the ferry! It freed up again and sucessfully completed the tour, covering some epic mountain passes. However by the time i was getting back on the ferry, it was making some horriffic noises and burning an ourageous amount of oil.

On teardown I found this:
https://lh3.googleusercontent.com/pw/AL9nZEUOXINFgoL26aCxSnHbkBWeZPaEsDY3h5rgbj8r7yvBFk3AI_GIe88Tq07DfwOp4JeAPkQGFfC6TtXdfw4H0Cn1FJyrlhlIiK5puvYi_RFeEDBnPXTV0y3F9eevRe4sqNqROhwHdLa9ts4BAFs7iez7=w1378-h776-no

https://lh3.googleusercontent.com/pw/AL9nZEVBT2zWXc5Q6VwtL4wXLHECd05fRKbgGtxg7q6aGD0XGC9MEXgugv8kcEBi-INpRNowYEWBfI2Mi2ysml1MDV_lcPT7tK_5yUx0mEDNabIyf3VsozMqdHYfFinQUW-c9_ExlEOZ_2AAREyf9gI0ZXsi=w1378-h776-no

https://lh3.googleusercontent.com/pw/AL9nZEWsbMyochbvGiSGvUQkuULveJiafVMlocP33s9WQBwV_jdSdCYcQFOyL2fWaNC9fSR0NOVRAbrVqQ-lsNVlLNULv8BHvCAU94TGGfYa0dlc-AqeMcIZijVmqq-wmxf3-l9VScvFDdx73QAZ7B0pYbIU=w1378-h776-no

Video

Umm, yeah, there was a good 4mm of vertical play on that piston. Looking at the last picture, the seizure seems to have been a result of the piston cracking, noth the other way round. See how none of the heat was transmitted across the crack. Scrub one £200 Accralite forged piston!

It turned out Hitchcocks had a stock of barely used pistons they used during development so I got one of these. I polished the crown and eased/rounded any of the sharp points. This will probably have decreased compression a bit but should have benefits in gas flow and removing detonation points.


I also decided the electronic ignition was possibly a bit iffy (not so certain now) and put the points back on with a new advance/retard mechanism. I strobed this up to give the correct advanced timing of 32 degrees and confirmed the advance was correct.

https://lh3.googleusercontent.com/pw/AL9nZEW6hQouDBgO40fINuAkZZ-3S_vJBdr5sZ7EZ1R5M9W5AFh7T0drKn8k_9uiOREPzV0DTwTTZOZhb7mXQEdDB3LP50Svf0HhYQhUXRmiZI5tUDx_6v5odYtfr1nRYtXOK34UiyA57vSIyjXxlq7ZZMdM=w1378-h776-no

https://lh3.googleusercontent.com/pw/AL9nZEW4PlwkGmnP3Iq5tYob_noEqGen1S0PVg0K2ahJXhQwekKoxB8MYoCOJx68TYWAuL42Yxu2PbbyS03Duyq25lGDCp7WqcNa7T86kgDLERFQC8YBAl28IeP5RY453v5EKZ9vhDWPJldggXzhg1h0V4Da=w1378-h776-no

Also fitted stronger springs to the auto-advance so it stays in the retarded position for longer.

https://lh3.googleusercontent.com/pw/AL9nZEV18zR5p61gA4KrtrDwbu1nB4QDuktbZ7qoqpPnUMh8aPkwteQYkoLuyecxVNj7UNNpZdkkcRo5ApBJ09jJbxRVtIy-k3NTM7v4aXnOA8_ajNuB-GyrOFX9mgJxXVK5prp84IWWpxaGV0LbkA3opG6u=w1378-h776-no

Also finally got my TM32 carb! Long story, came from the US eventually. Stuck in baseline jetting supplied by some other enfield enthusiasts.

https://lh3.googleusercontent.com/pw/AL9nZEUYZxp64BnnvRSyNf9fwl2xuJeLS6qtbU6SdZpSdcbcdqCTVWWKC9pjbfiKarPYkLAt6IzSCfKgaf-6gzAeD0iin3d7YxMS3DmX2MEPkdEKs5RfaEWKbpg-7AfOPWNWG4PjT7Mp4RGN92oFZlIM0-Q2=w1378-h776-no
https://lh3.googleusercontent.com/pw/AL9nZEWsq9jkhr0rKULxLdkPiVjVcj15dFnNl6-jVen5YkKk_OceBk1uQ5fvM59J0z7HEb55nnNMyXE5wHSTXE0PEZR5be-OKYnxHQpEKeYZefBGxvRZEIq2d9FUSEQZu8pgwAJuIrD6Sjsb96X5VGsDfVtA=w1378-h776-no

It starts great but pinks horribly under load. As a temporary measure, I retarded the ignition until it stopped pinking so I could run it.

The bike made it down to the Dragon Rally and back through some of the most torrential rain I've ever experienced so the wiring is good!

Then came yet another bent pushrod!! I finally got this one beat though. Which admittedly did go via making a set of 7075 solid rods (unbendable but double the weight).
https://lh3.googleusercontent.com/pw/AL9nZEX33YdEWl9YugaFTuPPXHVPUhSsbnDchCQp7U70lbXb7ij76ee48CT8RJoMKg2XHGvQncMV67hqLvrtDZNJYa40AVUxevUSxLarlouKkucEWrfalYcasOjlgH_JZGW2FrYSZLud-Lj8meu1HtsNzwVV=w1378-h776-no

https://lh3.googleusercontent.com/pw/AL9nZEXNm_e0XH_0JOjVgesuEblA_58tQkYDBOH9kLrDiDdYB8BL0WgsenBBom8jvzfJiyL4c2NRvzWlir_8mJl9vIsdbWmsot4dryKBXyGs7mruIx_mB0MgWCP_DpLI_NPjnfFrL3cRWzQ9iH-EfMzOpJUC=w1378-h776-no

On closer inspection of the cams, it turned out the inlet cam wasn't making continuious contact with the follower. The performance cams have a smaller base-circle diameter than standard and the follower was bottoming out on the crankcase 0.004" off the lowest point of the cam resulting in it being wacked open instead of lifted open.

https://lh3.googleusercontent.com/pw/AL9nZEWsN5r8v_WuNBy5wKw3XQBwKoYr0vG4K_g3loCq-5VD-y5fxnZ96p_aSexqZXaFlGFocsz12WU54BvoH0iWYGFJjlX_ykpbjkUHHbeNsArfMIMAkTEHgJySGkCaWL4xe40TfL5zT6K4sWJNGi4QWMHJ=w1378-h776-no

This was fixed by removing a small amount of material from the crankcase with a die grinder so the follower can drop further.
https://lh3.googleusercontent.com/pw/AL9nZEWs5F5zVwSFHavASNYQ8jkwJTYGBVZbfxoHE8eunh_tt4cdbf7gX3MBbkTR_-rb7j3NastztPNgyb_UkPjyqB1LWQLKmoYQaYmnaVFXmVY3yal-oWruHndUuuW_dOPfqUle3vBVeAgflO_CpVZhbibs=w1378-h776-no

It also became apparent that the fuel flow from the standard tap was woefully inadequate. i went full nuclear here and fitted a pingel tap which to quote my mate "Is like turning a bucket upside down". This will empty a full tank in 3 minutes.
https://lh3.googleusercontent.com/pw/AL9nZEXDj_n-9cHlX-5RecKHIIfv9jEH8ntrX7jtfEfWXYeEGyYnm61pIVd-ph9GNRKSx-2ENjBDgjV0yYPyKoqwDV-qOSGZppEI9MgR6bO1FZMHfGFputMDKbXJ-vCVe-A6FzpNxARNqXgdfLbOTMFy30Vw=w1378-h776-no

And that was another year gone. Put a few thousand miles on it and time for another summer holiday. We decided to do Northern Spain and Portugal again.

Would you believe it, got 20 miles from the ferry and it conked out, in almost the exact same spot!. This time though it was quickly traced to the battery lead having come off. Two days later it conked out again because it turns out the intermittant battery connection had fried the reg/rec and I had been running on total loss. No matter, a spare battery was procured and I just charged it every night. Fantastic tour of the picos and Portugal and the bike ran brilliantly.

https://lh3.googleusercontent.com/pw/AL9nZEXuQSbK2yqPQ5dKx8_hoAvIkrzDqBT3ZRXJeKuy2KmqNU3rEVjfAPJUWZwZu47wNinoFOHaascq0Eo7B-OpzPGog-oZE4VUFeATew4RiuZ0tBoth45k3sQFwD9QJ2cClGTAahxTHoxGCVh9d5JQfpFv=w1378-h776-no

Made sure the battery leads wont come off again!
https://lh3.googleusercontent.com/pw/AL9nZEW4iGHzdw1b3rhQARkDbr-d5PelGWIgV_it58ks0vfmXfxb4To0t2zjPmCBWBbBp5MfItiNCAt9PtmEdU4BMXBOh4dSikxCk3kaTtiuDlvVAstQJubmCshplP6x7w8Ui2jesUS4bf2nNjyRTMbuBfbY=w1378-h776-no

https://lh3.googleusercontent.com/pw/AL9nZEXGNLzXk2qSAAPgieoPMrZHrjk-itqOVCmUuUNz_SqLmpZabgN8s5XiQjivzFRXEaa5iLWdccbVpP2jzij3y0No2gEAxibkpBKZuOOX5zUrxQXIZiR83dVM8RLRFmwNkUnSp1U7Ah6pxMCCHVvSdIWP=w1378-h776-no

Which brings us back up to speed. The observant will have noticed I've been running it with the ignition retarded for the last year. Not ideal. I feel it is down on power from where it should be and perversely, it's hell of a latchy to start where it fires up first kick with it properly advanced.

So with the timing set where it's supposed to be, it's time to commence the enormous faff which is setting up the carb. There are 150 possible jets, only one of them is right!

Step one is getting the throttle positions marked and baseline it. Trouble is, it pinks under load anything over 3/8 throttle so i need to get that sorted first. It's fine up to 1/4 so the pilot jet must be in the correct ballpark. I've tried a larger and smaller one and it was worse.
https://lh3.googleusercontent.com/pw/AL9nZEW3jfkM0VyBUjC5LtD7zAnDIQOZo-t3pE2tTOljfniufhUnFFEyMdBJFIU0rOjKiVKNa2SI8VmyqM0XsO6NWMdtHyIOazM-Y-8pRkhr94a8s-1IQnm7pg2zoGPr08YKVNyp7SJv17VXGxCRmMHqDqdI=w1378-h776-no

Thing about Mikuni flatslides is they are a very known quantity and if it's lean between 1/4 and 1/2 throttle then we're looking at needle jet size, Jet needle taper and position and possibly throttle cutaway. Every performance bullet I've asked about is using a #4 slide so I'll stick with that. About to fit a P4 rather than P6 jet needle and a more aggressively tapered needle which is what a coule of Americans with "fireball" tuned bullets are using.

Once it's running nicely up to 1/2 throttle I can start dialling in needle position and main jet size. This will be a long-haul! Can't even dyno/plug-chop/GPS it until I'd got the pinking under control.
https://lh3.googleusercontent.com/pw/AL9nZEWH3W_kp4LJnYaCpYIFt6glfOs4tvVxCt7y2h2iOZd4M3PYIu4DdoBFxinLW2CSL0WmW35iAaX6GQE_9nQ1zVaJxZO8L2dBAg0QxKqnX6Cd8KwyqlWp7Yk2fm2LPR9MhFG8AeSxtFiFVVLMSddC44Ln=w1378-h776-no
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.
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