Hi guys. I'm Ben from Queensland, Australia. Background is Hot Rods, Kustom Kulture and few custom bikes over the years. Been riding and racing bikes for 25 years. Mainly Enduro and the odd motocross but always had a soft spot for British and classic motorcycles thanks to my late grandfather.
Mechanical Fitter and Boilermaker are my trades, so it goes somewhat hand in hand with my hobbies!
2004 Bullet "E" 500 with 5 Speed Box.
The current specs of it thus far.
Stock Head, Valves, Cams.
Hitchcocks Accralite 535cc +20 piston.
Alloy Barrel.
Hitchcocks Steel rod, roller big end.
All Bottom end bearings replaced with Japanese bearings.
Genuine Mikuni VM32.
Modified Rectangular airbox (larger intake ID) all fully seal TIG welded with DNA filter.
Pazon Electronic Ignition.
Hitchcocks larger pump discs, spindle and worm gear.
The rocker feed pipe lower single section has been replaced with a larger ID pipe to take advantage of this.
A "Bun Breather" style Breather system and separate timing chest Breather filter all with non return valves
5 speed box.
Hitchcocks 5 plate clutch kit.
Gearing is 19/38.
Day I got it
First issue of the bat was a crack that had formed in the front rim.
A friend in the Royal Enfield club had a NOS front hub and spoke set. So I whipped up a frame, spun up on the lathe some axle centers and got to work. Manage to true the wheel under 15 tho each way. Good enough for something that probably won't see 100mph!
Next came sorting out the breathers. All breathers bar the crankcase breather hose was blocked off by the previous owner, Which was not good for the gaskets and seals. This thing leaked like a siv.
Got the Hithchcocks crankcase breather/oil return kit.
TIG welded up the old airbox which now is a toolbox and mounted a bulk head fitting and breather filter for the timing chest. This is based off the "Bunn Breather" System. The timing chest breather the Non return valve allows the breather to draw air in through the Filter mounted in the toolbox but doesnt allow oil to be pumped out of the breather.
Also fitted anew seat, I had to turn up some bosses and a hinge for it. But turned out like it belongs there.
Nex came the DNA filter for the rectangular airbox. I also welded a larger ID neck onto the airbox along with fully seal TIG welding the whole thing.
Mounted the Genuine Mikuni VM32, also had to turn down the mounting flange, countersink the bolts and use a genuine Mikuni Rubber. To get the carburetor closer to the engine since the cable was having clearance issues but now fits a very snug fit!
Photo of the sealed airbox, back from the powder coaster. All mountedup looking like it belongs there.
Fitted the Hitchcocks oversize pump discs, worm gear and spindle kit. Felt like an age to lap those in!
But what always bothered me was the lower section of the feed pipe. The lower barb fitting that screw into the case is a larger ID than the actual lower section of the feed pipe. So I matched the ID of the case fitting to a new lower section of feed pipe which would be major restriction.
Old vs New Lower section of rocker feed pipe.
Now this was a odd material, I ended up TIG brazing the pipe in, no leaks or cracks! Here's the end result after giving it a light sand to get the chrome coating off.
Topic: "Rocker" Bullet 535 (Read 14105 times)