[HowieUK]

I have had a problem with the bullet since I first bought it.
When the engine had warmed up after ten minutes riding, a noise started that sounded like a tappet problem. It didn’t really affect the running of the bike and I had a few mechanics adjust the tappet clearance gap on the travels around the north of India but it never went away. When the bike started from cold it sounded great it was just when the engine got hot that the noise started so I put it down to some sort of expansion of metals problem. The problem seemed to be related only to the inlet valve and not the exhaust (outlet) valve.
Travelling down South from Delhi through Rajasthan it got slightly worse and if I stopped the engine for a few minutes whilst the engine was hot, it became very difficult to start again until it had cooled down for an hour. Through Gujarat and Maharastra I started to have to take the spark plug out and put petrol into the cylinder before it would start whilst hot because when I checked the spark plug it was dry. At first I thought this was not connected to the other problem because I once ran out of petrol and thought that some debris was lodged in the ‘carb’ or the filter. Once I arrived in Goa I had yet another mechanic put on a new petrol filter and he talked me into having the tappets adjusted yet again.  After this the bike would only run for ten km’s without stopping and the noise that sounded like a tappet problem increased quite a lot. I had already had the inlet tappet changed and the push rod changed in Manali so I thought it must be a faulty inlet valve that was the cause of the problem. I went to yet another mechanic in Goa and tried to explain the problem and told him I thought it was the valve itself that was bent. I insisted after any work was done it was taken for at least a five km test ride. When I went back next day instead of removing the cylinder head he had gone through the usual exercise of just adjusting the tappets but at least he had taken it for a good test ride and seen the problem re-occur.

He took off the head and I had the valve seats and new guides ground and re-set in Mapusa. He put it back together and it seems to be ok at the moment but he left it until then to tell me there were marks on top of the piston where the inlet valve was hitting the top of the piston which had been the noise I was hearing all along (Why he told me at that late stage I don’t know?)

So hopefully having the valve seats ground will give me a slight bit more clearance but does any one know a long term solution if the problem re-occurs?

Howie

Edited by HowieUK, 08 November 2006 - 04:25 PM.

[vinayverma]

Hey Howie,

hope the bike is fine now...Keep us updated.
Cheers
Vinay

[mira4bai4]

Howie, hope that your bullet is better behaved.  I to have had similar problems since I purchased my 500 in April and this past week while riding to Pushkar my head warped after the head gasket was replaced the previous week.

In reality the only solution to both our woes is to go to Bullet Wallas and have the engine rebuilt to better specifications; also avoid the Enfield service centres as they are the real source of our problems with little idea about doing a proper job, that is unless someone possess a torque wrench and feeler gauges as without these basic tools the engines fate is pretty much set.  Oh and I should add, that they know how to use them as the training is really terrible and they use bad gasket sealant that does nothing if they use any at all.  They are also prone to damaging parts, threads and throwing oversized nuts on at a whim so bear this all in mind on your next visit.  Keep them eyes peeled for any hanky panky!!!!!!!!!!

bulletwallas

Edited by priya, 10 November 2006 - 07:30 PM.

[iwanttogoback]

completely off topic, but a big welcome to the tree mira:) wondered if i'd ever find out what happened to you.

[HowieUK]

Thanks Mira,

I was beginning to accept that a total engine stripdown and re-build would be the way to go, that I of course want to avoid like the plague!

I'm sure i've heard in the past that the pistons can be 'shaved ' down but I don't think you would get the compression required if you did that?

Is this a fault in the later models or just 'one of those things'?

Howie

[mira4bai4]

I am not sure if a complete rebuild is such a bad thing, it will cost of course but compared to the ongoing expense of a bad engine it would be a cost saving action in the long run.

My engine has cost Enfield and others nearly Rs 30,000 by now and thankfully I still have half of my warranty to go.  So looking at the options and what Bullet Wallas can do rebuilding the engine to a higher standard using far better quality bearings, precision engineering to ensure that everything is as good as it can be, given the casting of the engine parts it seems to me to be the best option for the future.  I would not worry about a loss in compression as your engine can be increased in capacity during the process if you so wish.  Check out the web link as it has some great info on what is possible and would be seriously worth consideration.

Essentially, in the last 5 years the quality of production has dropped, the 500's have suffered the most and the service training is really basic.  As I am sure you and many others have spent a great deal of time in their workshops which are to say the least pretty scruffy places from what I have seen, observing the techniques applied to mechanical servicing is an eye opener and it makes one want to drag the beast out to save it from their clutches.  I have had brand new engine housing made to look old within 5 minutes, my seat torn, tank scratched and numerous things scratched in front of my eyes.  When it comes down to the actual servicing, it is always at the barest minimum and some places do not even check your oil levels when pulling the head off.  They will not clean the valves or the piston unless you make a lot of noise and generally it is a constant battle to get simple things done correctly.  Customer Care at present sux big time.  There is a high level of complacency in the company and they are still riding high on their past image but that is fast becoming tarnished.

So why am I saying all this, well presently I am at war with them, a gentle one but none the less we are in conflict while still on friendly terms.  I am demanding a new engine and they are being difficult, but it will end up in the consumer court if they continue to be stupid about it.  Tomorrow I have a conference call scheduled with various heads of RE to sort some matters out, but through it all I am trying hard to show them and guide them in ways of improving there service and profitability before they fall flat on their faces.  It is all give and take, I will take a new bike, money or an engine; I will give them service training programmes, customer care training programmes and marketing programmes but at a price of course.

[mira4bai4]

iwanttogoback, on Nov 10 2006, 07:09 PM, said:

completely off topic, but a big welcome to the tree mira:) wondered if i'd ever find out what happened to you.

Thanks for the wondering.  Actually once I got to India and getting caught up in the swirl of dust and pollution that constantly surrounds Mohali, looking a little like Linus from the Peanuts cartoon; I found that everyone was doing a grand job on the forums that being an observer of what life is really about here was showing that I new nothing of it all and only judgements could be offered which I still do not feel comfortable about unless I have some experience and at least in mechanics and customer service I do.  

Ask about driving in this region and I shall rant for some length, did I mention the pollution, well I could go on; was respect discussed, well that is a low scoring subject here abouts also.  So if anyone knows of any rentals in Shimla to relocate to we would love to know ~ God give me air to breath.

[Hippie at Heart]

Howie, as suggested by Mira it is best to hand over your bike to a professional engine builder and personally supervise over the operation. If am not mistaken you were referring to a ‘grinding’ noise that is more acoustic when you are saddled? If you have seen nicks and cuts at the piston crown have you tried to discover if the matching marks were there inside the head around valve area too? I don’t think shaving off the crown head by few micro millies will offer you any respite because that would severely effect the compression ratio and overall increased head volume wont do any good since it will be a generic exercise without any consideration to the squish band. I would suggest a pushrod and small end bearing overhaul and a best quality head gasket money can buy. All said and done a bullet is not macho bike as advertised and perceived, but a dainty that should not be pushed around beyond a point.

[HowieUK]

Sorry about the time it's taken to reply!

One thing and another has conspired to keep me from the internet.
I think I will be putting a re-build into the hands of a bullet-wallahs mechanic in the South of India when I go to re-new visa in February.

Thanks for all the advice

Howie