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  1. Kojack

    2003 Royal Enfield 500 Deluxe

    "But even then you can see the measure isn't quite straight in the mic." Raymond, I've seen two styles of standards. The cheaper ones have flat faces and should end up square in the micrometer. The better ones are ground on a radius. Those are somewhat easier to use, in my opinion. Both are...
  2. Kojack

    XS650 Craigslist postings depository

    https://www.facebook.com/marketplace/item/1072385083736494/?mibextid=dXMIcH
  3. Kojack

    2003 Royal Enfield 500 Deluxe

    Normally most wear is at the top of the cylinder. That's where the explosion hits the piston and creates all sorts of multi-directional forces on it. I never used the ratchet. It creates too many inconsistencies. I would definitely never use it with a t-gage. It takes a light, gentle touch...
  4. Kojack

    2003 Royal Enfield 500 Deluxe

    I spent 25 years learning to use the mic and t-gage. I always, always took several readings to verify size. The other thing to be careful of is how much you tighten the screw on the gage. Too loose and it can slip back. Too tight and it can deform enough to affect the reading.
  5. Kojack

    2003 Royal Enfield 500 Deluxe

    It seems unlikely that the bore would be under factory specs. Perhaps it went out of round? Check across several areas and see if it averages out. If that's the case then it's probably better to bore oversize.
  6. Kojack

    2003 Royal Enfield 500 Deluxe

    I remember working in the machine shop. One day an apprentice came up looked at the micrometer I was using, and asked; " can I borrow that c-clamp?" That was a good laugh. 🤣
  7. Kojack

    2003 Royal Enfield 500 Deluxe

    Practice makes perfect. Use a light touch. Take several readings to confirm size.
  8. Kojack

    Whats your weather right now?

    42F. I put outdoor activities on hold below 50.
  9. Kojack

    2003 Royal Enfield 500 Deluxe

    Nothing like a fresh bore and piston. The last time I paid for a bore job was back in the 70s, and it was $8 per hole at the time on an auto engine. I wouldn't think a shop would charge more than one hour labor.
  10. Kojack

    2003 Royal Enfield 500 Deluxe

    Raymond, I just saw your post. Go the +.010", or bigger if you prefer.
  11. Kojack

    2003 Royal Enfield 500 Deluxe

    Jim, You're absolutely correct. However, Raymond's bike is low mileage. If he gets a feeler measurement within factory specs at the bottom of the bore, I'd say there's no wear at that point and check the top of the bore the same way. What would I do? Well, I have the tools to do a precision...
  12. Kojack

    2003 Royal Enfield 500 Deluxe

    Thar Hitchcock crank is beautiful, and expensive. For that money you could buy a fast Japanese bike. If speed ain't the goal I'd just go with a good piston and rings.
  13. Kojack

    2003 Royal Enfield 500 Deluxe

    As long as there's no up and down movement you should be good. A bit of side to side is normal for any motor I've seen. You can use the old piston skirt and a feeler gauge to check bore size accurately enough. There won't be any wear at the bottom of the bore. You can probably still see the...
  14. Kojack

    2003 Royal Enfield 500 Deluxe

    That seems reasonable and I'm sure there's no gouging going on. For future reference here's a pic of the late BSA style cable. Normally the switch is in a position to plug into the harness behind the headlight.
  15. Kojack

    2003 Royal Enfield 500 Deluxe

    Homework completed, Raymond. I noticed your issues with a front brake switch. Did you ever consider using one from a BSA/Triumph front cable? The type that mounts midway in the cable sheath.
  16. Kojack

    2003 Royal Enfield 500 Deluxe

    My headlight wouldn't come on unless the motor was running. Do I have issues?
  17. Kojack

    2003 Royal Enfield 500 Deluxe

    My apologies to Raymond and all. I didn't mean to hijack the thread. Since the Bullet ain't broke i ain't going to fix it and I didn't plan on adding more comments on it. I guess I could start a thread about myself, since I'm such an interesting and lovable character 😉, but I'm afraid it would...
  18. Kojack

    2003 Royal Enfield 500 Deluxe

  19. Kojack

    2003 Royal Enfield 500 Deluxe

    This afternoon I started by re-installing the air cleaner on the Enfield. Next, the freshly charged battery went in, sort of. This will take some more investigation but it's temporarily permanent for now. I decided to just fill the carb with gas through some tubing and fittings instead of using...
  20. Kojack

    2003 Royal Enfield 500 Deluxe

    Raymond, don't worry. I don't blame anyone but myself. I came to grips with my sickness/obsession long ago. Yes, it's a 500 with a neutral finder. The shifter should not be a problem. I have other bikes (too many!) with shifters on either side. Thanks for the advice on the electric start. I...
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