2003 Royal Enfield 500 Deluxe

Good luck with it. I'm the opposite really, I like working on bikes but don't really enjoy riding them so much any more. Combination of painful joints, terrible pot holes, even on main A roads and over crowded roads full of homicidal drivers. It isn't a great experience round here any more, sadly.
 
Bowing to the inevitable, just been out and done this.

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Best way I've set up for this messy job - as soon as you loosen the one central bolt that holds the primary cover, ATF starts to dribble along the full lower edge of the case. Hence the mahoosive drip tray . . .

Have previously thought about drilling & tapping the inner chain-case, fitting a drain bolt. I reckon that might drain about, ooh, 95-98% of the oil out? Since I need to pull that inner case now to sort the gasket, I guess this is the perfect opportunity to get it done and make the job less mess next time.
 
Raymond said:
Don't want to sell the Bullet, not until me knees give out and I can't kick anymore. Don't want to drain the primary which is a messy job and all the rest of it but I will. Family and friends think I enjoy working on the bikes. Sometimes yes but mostly no. Just want to ride it.
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Well Raymond, you can always spend more time on the sofa. I prefer lying on it. That will certainly accelerate the deterioration of your body. My vote is for the Bullet or whatever else might keep you active. I do very much enjoy your participation in this forum and actively follow along.
My own knees are improving as I force the issue of using them.
 
jetmechmarty said:
Well Raymond, my vote is for the Bullet or whatever else might keep you active. I do very much enjoy your participation in this forum and actively follow along.
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What he said!
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You, Raymond , are one of my favorite contributors on this forum. Your well written and colorful articles on a variety of bikes and subjects are always a welcome addition. And I always love the little glimpses of your beautiful countryside! 😃
 
Raymond said:
There will be a pause - off to Whitby, four days holiday. Seaside, fish'n'chips, Captain Cook, Whitby Abbey, Dracula and Goths.
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Have a good trip. We had a great week down in Pembrokeshire last week.

Sandsend beach just outside Whitby is a great place to watch the world go by. I'm sure you'll be fixing the Enfield with renewed determination after a few days break 😎
 
Raymond said:
There will be a pause - off to Whitby, four days holiday. Seaside, fish'n'chips, Captain Cook, Whitby Abbey, Dracula and Goths.
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I adore Whitby. The whole place is just a great area to spend time in. Best fish 'n chips in the world too. As a Dracula fan it ticks boxes for me.
Enjoy yourselves.
 
Back to work. Further dismantling. Home-made clutch puller:


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That's the clutch end plate, normally holds the six springs, plus a length cut from a thick bolt, three screws and a short bolt. The wee bolt goes in the end of the shaft for protection, and it works like this:


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Clutch out, now the dog can see the rabbit

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Decided to go ahead with my notion of fitting a drain. First drill 5mm hole at a low point on the inner case


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Tap for M6x1.0. Was thinking I would like a bit more strength, well I'm sure many of us would, but to reinforce the chain-case I wound an M6 screw from the inside, fitted a nut finger loose and smeared some JB Weld around. Plus, the nut should give a good perpendicular surface for the sealing washer.


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Tomorrow, I'll tidy the weld stuff and refit the screw from the outside with a fibre or copper washer. That ought to do. With engine hot and filler cap removed, shouldn't take an inordinate amount of time for the ATF to drizzle out of a 6mm aperture?
 
Raymond said:
Back to work. Further dismantling. Home-made clutch puller:


View attachment 351238

That's the clutch end plate, normally holds the six springs, plus a length cut from a thick bolt, three screws and a short bolt. The wee bolt goes in the end of the shaft for protection, and it works like this:


View attachment 351237



Clutch out, now the dog can see the rabbit

View attachment 351239View attachment 351240


Decided to go ahead with my notion of fitting a drain. First drill 5mm hole at a low point on the inner case


View attachment 351242


Tap for M6x1.0. Was thinking I would like a bit more strength, well I'm sure many of us would, but to reinforce the chain-case I wound an M6 screw from the inside, fitted a nut finger loose and smeared some JB Weld around. Plus, the nut should give a good perpendicular surface for the sealing washer.


View attachment 351244


Tomorrow, I'll tidy the weld stuff and refit the screw from the outside with a fibre or copper washer. That ought to do. With engine hot and filler cap removed, shouldn't take an inordinate amount of time for the ATF to drizzle out of a 6mm aperture?
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Good work Raymond, nicely done.
 
This morning.

Method for torquing the clutch nut.


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It's worth noting that some people don't think it's necessary or appropriate to use a torque wrench on a on Royal Enfield. But If I'm going to make something tight, I want to have some setting to aim for, not just as tight as possible. The three bolts that hold the inner primary were torqued to 8 ft lbs and the clutch centre to 40 ft lbs. Takes the guesswork out of the equation hmm, that needs to be tight, but uhm then again, Indian metallurgy . . .


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Next the alternator and the clutch.
 
Raymond said:
Next the alternator and the clutch.
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With those fitted, outer chain-case fitted, 400ml ATF lobbed it were time to test. Shoved the Slug into the yard and started the engine. Selecting first caused a stall - spent time adjusting clutch and it's much better to the point it does not stall when a gear is selected. Still a few little things to do before attempting a test ride but that was enough for today.


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Hoping the leak at the crankcase joint is fixed, this time the drip tray is a precaution. No oil when I last looked . . .
 
Mailman said:
You’re getting an education on these old RE’s, you’ll have to open a little repair business when you’re done. 😉
Just curious, have you ever seen any other old Enfields in your area?
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Never seen an old one around here. 'Case there's any RE stalwarts around, better explain my use of old -

to me - an old Bullet means pre-unit Iron barrel, manufactured UK or Madras, basically all made to the same design with very few changes over a production run from 1949 - 2009.

Purists might limit old to UK made models which would all be pre-1967?

And some folk think the UCE bullets made after 2008 are old because they are mostly a redesign of the pre-unit Bullets into unit-construction form.
 
Gratified to find the drip tray devoid of drips this morning.


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Fitted the battery box badge


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Adjusted the clutch until a gear can be selected without stalling and went for a short test ride. It was short because although first selects, second took two or three stamps on the lever, third and fourth didn't want to know at all. About 1 1/2 miles around the village in 1st & 2nd.


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I'm hoping adjustment with the mech under that r/h gearbox end cover will let me use all the gears.
 
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