[pushrod]

 Looks like Ace nailed it https://www.lowbrowcustoms.com/british-standard-jrc-30mm-carburetors-pwk-keihin-replace-amal-930-and-mikuni.html

[Adrian II]

My airbox connector hose probably wouldn't stretch from 45mm to 50mm,.and the 57mm hose would be too big.

Now THIS might work, a 57 to 51mm reducing hose, the extra 1mm at the carb end would squeeze down well enough without too much protest, just a decent clip. A purist might want a strip of shim around the carb mouth. You might be able to find one of these in black.



ttps://www.ebay.co.uk/itm/New-Blue-Silicone-Hose-Straight-Reducer-57-51mm-by-ASH-57mm-to-51mm/200981314501?hash=item2ecb6b7bc5:m:mAvE0Qnhg-G14EFKTmlZsNg

A.

[ddavidv]

Corrected measurement with digital caliper 48mm.

Another subject. Front brake handle is very floppy. Took it off and the pivot pin is very loose inside the handle. Being aluminum I'm wondering if it is the lever hole that is worn? I doubt I can find a bushing to tighten it up.

[Adrian II]

Being aluminum I'm wondering if ...

So you're made of aluminum??? 
 
New front brake lever assemblies can be bought cheaply off ebay, it's probably not worth trying to fix it .

https://www.ebay.co.uk/itm/ROYAL-ENFIELD-FRONT-BRAKE-LEVER-ASSLY-SWITCH/333166500255?hash=item4d9245599f:g:-wQAAOSwMpFcLLra

A.

[ddavidv]

The questions keep coming (and I have several unanswered, if y'all want to scroll back through). Mine came with essentially no battery so I have nothing to match up at the battery store. Can anyone provide the size/model? Batteries usually have a 'group number'.

[Adrian II]

According to the on-line parts book its a Yuasa YB14L-A2 132mm x 90mm x 168mm.  Now cross-reference that with the Motobatt list and buy their AGM version, which is a big improvement.

A.

[ddavidv]

Replaced the primary chain last night. There is NO WAY the chain in there was for that bike. New one adjusts out perfectly.

If it weren't for fixing all the PO 'repairs' this thing would probably be running by now.

[Adrian II]

There is a certain satisfaction to be had from seeing various screwed-up things put right, however frustrating it is when you first find them.

Something about the Bullet seems to encourage this kind of thing, unfortunately.

A.

[Arizoni]

Replaced the primary chain last night. There is NO WAY the chain in there was for that bike. New one adjusts out perfectly.

If it weren't for fixing all the PO 'repairs' this thing would probably be running by now.

Sounds like the previous owner was a guy who believes in the old saying, "If it isn't broken, fix it until it is." 

[ddavidv]

The 'fixing' is sort of the point of this project so ultimately I don't mind it. What is a bit off-putting is the idea that, had I not decided to check the fluid level of the primary (there wasn't any!) I never would have found that chain flopping about. Scary. I can't imagine the backlash on/off throttle.

Today's question:  how do I fit a battery to this thing? PO had stuck some tiny gel type battery in the left tool box which I'm not keen on. There is no battery carrier. I found one on Ebay from a '99 but according to Hitchcock's the correct one for mine is "Electric Start Only" which leads me to believe the earlier one may not work. The proper one is very pricey.

Without the battery in place I'm uncertain of the clearance for an air cleaner. I've found this one but wonder if it may be too big? https://www.ebay.com/itm/High-Quality-Metal-With-Rubber-Connector-Mushroom-Head-Air-Filter-Cleaner-48mm/202515518206?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2060353.m1438.l2649

Edit:  I found this photo from an older post showing a battery mounted in the left tool box. I'm becoming more okay with this idea if I can figure out a way to secure the battery in there.

[ace.cafe]

The battery carrier is different for the ES models because the ES uses a 14ah battery, and KS models use a 5ah battery. Significant size difference, but they both mount to the same frame lug.

There is plenty of room for an airbox or filter because the airbox mounts to the same frame lug as the battery box, except on the other side of the frame.

[Adrian II]

The electric start 14AH battery box and cover, they are available in chrome or black.

https://www.ebay.co.uk/itm/14AMP-BATTERY-BOX-CHROME-COMPLETE-ASSEMBLY-ROYAL-ENFIELD-CLASSIC-UK/222165679697?hash=item33ba1b3e51:g:ZC8AAOSw3YNXbo7B

A.

[ddavidv]

Where do the turn signal relay and the starter solenoid attach? Both seem to have a rubber holder with a slot in it like they would slide over a metal tab on something.

[Bilgemaster]

Where do the turn signal relay and the starter solenoid attach? Both seem to have a rubber holder with a slot in it like they would slide over a metal tab on something.

I've got a reasonably unmolested 2005 "Military". If this long patch of rainy misery ever lets up, I'll see if I can't get a couple of clear shots of the relays and whatnot in situ. In the meantime, here are the pages of the "Switches and Fitments" section (13 - 20) of the Spare Parts Catalog ...

[GlennF]

The size and type of the battery you need is not a set thing. It is going to depend partly on how often you intend to use the electric start and under what circumstances.  Obviously a summer only once a day ride that is usually kickstarted (unless you stall at the lights and need to get away quickly) will be a lot less demanding on the battery then something that is electric started multiple times a day all year around for example.  Too small it will not handle cold weather electric starts. Unless you go stupidly oversized with a battery (in which case the charging system may have issues if it runs flat) the only issue with big is physically fitting it.  Also, if the bike is likely to sit for long periods without being ridden an AGM battery loses less charge per month but costs more.