[thefastelephant]

UPDATE #2

Installed the Racedynamics Powertronic ECU V4 (launched Nov.2022)

Just like the previous Powertronic, I tucked the unit under the fuel tank. Enough clearances. Wiring was laid along the factory harness. Excess connectors all tucked above the Fuel Injector between the head-steady brackets. The tank needs some push forward when aligning for bolting its frame bolts under the seat.

Rode her around today after the install and it seems the idle needs to be taken up as it stalled and twice in a short ride with stops upon start-up it goes off with a intake pushback kinda noise. Also while riding I noticed a bit of fuel starvation under 1500 RPM in traffic conditions.

Calibrated the TPS Sensor as per manual. The first start-up happened with the stock check coupler and it fired up at half kick.

Have upped the idle and left it, will test tomorrow.

[thefastelephant]

UPDATE #3

Took apart the Cylinder Head for mathcing and polishing the ports and getting rid of the lips at the valves in combustion chamber, managed to get the combustion chamber part done last night itself.

Removed the Barrel for machining, measured the deck height with piston at TDC, it was 2.2mm so shaved off 1.7mm leaving 5mm on the barrel. Addition of the cylinder head gasket which is 0.5mm thick makes the squish at the desired 1mm.

Cleaned base of the the barrel mating face, putting in a new gasket as per SOP.

Once the ports on the head are matched and polished, will cut valve relief pockets onto the stock piston and then polish the whole piston top too since am at it.

Here's some of the progress updates of the Barrel and Combustion Chamber\

[Taurim]

 

Some work remain to be done on the head to "unshroud" the intake valve 

[thefastelephant]

UPDATE #4

Finally sent the head to a competent "Head Work" specialist. The exhaust valve had a bit of play so getting the guide's replaced. Also the seats lapped with new valves and stem seals.

Polished the Combustion chambers, Inlet and Exhaust ports with their tracts to the best of my ability. Was unable to procure sanding flaps or cone sanding cartridges to did the best I could and wrapped up the port work.

Polished the piston too. Was going for a mirror finish but will settle on this for now.

To summarize the works done:
a) Combustion Chamber Polished, removed the "raised lips" around the Intake and Exhaust Valves and matched to surface finish
b) "Unshrouded" the intake valve since it ran too close to the walls
c) Matched the Intake Port to Manifold and Adapter, also enlarged the intake tract bore to the bore of the intake manifold
d) Enlarged the Exhaust Port and tract to match the "Copper Gasket" that seals the header pipe
e) Combustion Squish mod: Shaved 1.7mm off the base if the barrel as the piston to deck clearance was at 2.3mm. The piston at TDC now is 0.5mm from deck
f) Cut Valve Relief Pockets onto the stock piston with 2mm extra diameter than the valve face for "Wiggle" room and 2mm in depth too
g) Pushrod Height Reduction by the same 1.7mm

Did a compression test with a "Shady" compression test gauge and I could see 120 PSI however this is with my "battered" valve seats and valves as I did make a mess while using the rotary tool and carbide burr. Will do another compression test this evening at the time of assembly with new guides, valves and seats freshly lapped.

Before anything else, I sincerely want to thank all the forum members and contributors to share their knowledge, experiences and inputs on all other threads to enable some enthusiasts like myself to learn more about motorcycles and their performance upgrades and maintainence.

Special credits to Taurim, Bullet Whisperer, Karl, Ace, Gizzo, Derrotone and Guaire as your responses have really helped me to shape my thought process before and while going into this upgrade/mod.

I shall have saved enough by June 2nd week to get her onto a Dyno for tuning the Powertronics unit and understanding the power figures. So far the following is the price of the stuff I paid for here in India:

1) New Intake & Exhaust Valves: Rs.650/- [USD 7.95]
2) Guides, Stem Seals + Lapping and Machining Labour: Rs.1,200/- [USD 14.68]
3) Porting Tools (WD40, Burr, Rotary Tool, Lapping Paste, Polish, Sandpaper, Microfiber Cloth etc.) = Rs.5,500/- [USD 67.28]
4) Barrel Machining for height reduction: Rs.250/- [USD 3.06]
5) Machining Pushrods for length reduction: Rs.200/- [USD 2.45]
6) Engine Oil & Oil Filter Assy. since I'll also be replacing the oil: Rs.900/- [USD 11.01]
7) Gaskets for Barrel and Head: Rs.550 [USD 6.73]

TOTAL: Rs.113.16 USD or Rs.9,250/ rupees (a.k.a a third of my monthly take home :p)

Also, one thing I did different is I machined the push rod by removing the top part of the Pushrod (the one where the rockers press down on) as it was easier to pull since I didn't have mole grips. A heat-gun and a C-Clamp did the job.

[thefastelephant]

UPDATE #5

Was assembling everything up again last evening.

Got in new Valve guides and had the seats cut and lapped.

Once the Piston, Barrel and Head were torqued, I install the Rocker Bearings.

Interestingly, the bike fired up without troubled but as soon as I started torqueing the rocker bearings it kept dying.

After sorting the checks for spark and fueling, I loosened the rocker bearings.

Turns out the Inlet side tightened up well without trouble but the exhaust side rocker bearing seems to be pushing the valve a little too much at closure causing compression loss.

Since I don't wanna meddle with the pushrod now again. Making a shim temporarily (am not so pro on the shim method) however will get a new pushrod and make it shorter.

[gizzo]

If you tighten the rocker blocks down and leave it alone for a few hours with the valve open, the lifter will probably bleed down and you'll be golden.

[thefastelephant]

Hi,

Any idea why this happens. Its so sensitive. Almost 1/4th turn of the rocker block on the exhaust side and it looses compression.

I am not mistaken, the valve remains open due to this "lifter pump up"

Meanwhile developing lasercut shims

[gizzo]

Hi,

Any idea why this happens. Its so sensitive. Almost 1/4th turn of the rocker block on the exhaust side and it looses compression.

It just is. Did you give it time to bleed  down and try again? The shims wont do any harm (I use them on mine) if the pushrods are still too long after shortening.

This all assuming you assembled everything correctly. Maybe they cut the valve seats really deeply and the valve is sitting higher than it should. That'd be some sloppy machine work though.

[thefastelephant]

So I did leave the exhaust valve at open for a night.

No luck. The kick went down without any pressure.

1mm shims on both ends since I was at it and she starts better than earlier (less kick travel and pressure)

Also, the idle is more stable than earlier. All this on the stock ECU.

Engine gremlins seem to have taken off now.

Riding her out today for over 120 kms.

Hoping I don't run into any trouble.

[gizzo]

That's good. Sounds like something's changed with the machining.

Going by the price you paid for the new valves, I'm guessing you didn't buy the H's stainless 1 piece items. That's a shame seeing you'll be chasing extended high RPMs. Good luck.

[thefastelephant]

Am confused between H's and Ace

Have messaged but no response from G

[gizzo]

Am confused between H's and Ace

Have messaged but no response from G

H's is shorthand for Hitchcocks.
Fitting this 1 piece exhaust valve is a smart move.
https://accessories.hitchcocksmotorcycles.com/21501?cont_page=Royal-Enfield-535-Continental-GT-Accessories&keyword=valve&year=2014

[thefastelephant]

Is this the one that comes in the 535 valve and spring performance kit by H's?

[gizzo]

Is this the one that comes in the 535 valve and spring performance kit by H's?

Yes but available separately as in the listing above.

[Marcosgt]

New King and day my best pal moves on.

Arthritis of both hips has forced sale of my Conti after two years of rebuild dramas and fun days out.

At 70 years it seems my days of polluting the atmosphere and back-firing have passed and will have to try and find a car which replicates some of the emotions felt aboard this lump of iron.

I would like to thank you all for your sage advices, candour and comradery over this period and wish you all safe speed.