Hi guys. I'm a frequent poster I've got this 2004 Bullet 500 "E". It's seen loads of extensive work all detailed in it's own thread in the Iron Barrel section here. It's been a lot of changes and upgrades and here sooner than expected, it's going through some more
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https://forum.classicmotorworks.com/index.php?topic=32484.0Although this new engine build would be more appropriate here in this section since it's heart is going to be more Electra than Iron Barrel.
So this point in time came sooner rather than later, which I was not expecting.
The Cylinder is worn out! Piston rings are still sealing at 165psi, but when I stripped the head off to pop on some valve guide seals. I gave the piston a wiggle and had 0.5mm of breathing room.
So the bore is done. That last light hone to get the new rings to bed in was the end of it. Especially being 535 +40 oversize.
Which concludes that venture of its Iron Barrel life.
I've had a Electra X 500 head in my possession a while now just sitting on the shelf staring at me. So now it's time to crack on with it's next iteration of this bikes Evolution!
I managed to score the Head and !!Brand New!! Hitchcocks 535 Barrel within our small circle of Royal Enfield enthusiasts here in Australia.
Pictured is Left is the stock GT535 piston and right is the Hitchcocks Accralite 535 piston with a raised crown.
In typical AVL head fashion the valve seats are proud of the casting. Also the inlet port is bigger than the inlet valve seat. So the seat will need will need removing, filling with weld and seat re-machined and installed.
I found that UCE valve spring assemblies can be used. So I'll be opting for a Hitchcocks UCE competition valve spring set. Unfortunately UCE valves vs AVL valves are so close, but no cigar. Their dimensions match utill the last segment after the collet groove on the stem. The AVL valves are longer. The GT535 inlet valve is only 1mm bigger. Exhaust is the same.
I did email HMC asking if the UCE vs AVL valve guides are the same but apparently they are different also. I was hoping I could use some Phosphor bronze valve guides. I'll see if there is any on offer.
For head work. I'll be basically copying my GT535 head. It has yielded great results. It went from barely being able to reach 80mph to now it cracks 100mph. 102mph when it hits the stock redline. The combustion chamber is very similar to the Electra X/AVL 500 head. Basically tidying it up and un-shrouding the valves to promote better flowing (Bullet Whisperers Technique). Get those valve seats sitting flush. Tidy the ports, especially the inlet port. It's pretty big in diameter as is! So I won't get hungry and take that out larger. It will remain the 34-35mm mark the best I can.
The exhaust port has a lot more room for improvement. At present its around 27mm. The seat measures 30mm. So I'll open that up to 30mm all the way through.
Here's my GT535 Head for comparison.