Hi guys I need some advice, I will be building an performance engine with B.W.
But I have some questions.
I have a 2004 Bullet 65 500cc Trials 5 speed, which is electric start. The bottom end we are going to use in the new engine is an kick starter model.
What we want to know is our options? would I be able to put an electric start primary case with all the internals of the electric starter primary onto an kick starter engine, with the electric starter? Is this possible? Or is there a better option?
Bin the Electric Start system in it's entirety. They are problematic and fragile. Their failure is not a question of if but a question of when. It may survive a hundred kick backs or none.
Do we need to tap new threads to mount the electric start inner primary case onto a kick starter bottom end? Either with or with out the electric starter?
Yes. Three holes.
Best is to use a kick start primary, no drilling required.
Is there a difference between the engine sprocket from an electric start primary case or kick start primary case.
Yes, E/S engine sprockets are wider with extra row of gear teeth in order to accommodate the gear train of the E/S. A decent machinist can remove the extra row thereby narrowing the sprocket to KS standards. It will then fit within the KS primary.
Is there a difference between alternator rotor spacers from an 500cc electric start engine and a 500cc kick starter engine?
I seem to think so but don't remember accurately right now. C,c,c,cold ! Let me warm up for a bit.
Also will I be able to put a left shift 5 speed gearbox onto a kick starter only engine? Which originally had a 4 speed box?
Not easily. Either an oil tight passage though the crank cases in the oil tank will have to be invented for the shift shaft to pass through to the left or a mouse trap of linkages going over and around the back half of the engine would be needed.
Right hand shift conversion is easier and much more cost effective.
I already know the rocker oil lines are different between electric start and kick start models.
Easy to mod those. Also ES heads can be drilled and tapped for the larger banjo bolts of the KS oil lines. KS heads can be bushed for the smaller ES banjo bolts or the larger KS banjo bolts themselves can be drilled and tapped to accept the smaller ES banjo bolts. A simple distance piece in this case takes the place of the former large diameter banjo fitting and held tight by the large banjo bolts. The ES fitting and bolts are then installed.