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Thread: Rebuilding Royal Enfield Bullet 1996 cast iron

  1. #1
    Addicted davidlivi's Avatar
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    Default Rebuilding Royal Enfield Bullet 1996 cast iron

    Hi friends. This is my second restoration, first one being Yamaha rx 100.
    Being a DIY guy, 'll post the process of restoration.
    The bike has been dismantled completely. Engine crank case has been given for sleeving to stop timing shaft side leakage and other parts for painting.
    Hope you guys enjoy the journey with me..😀
    petrolhead_chn likes this.

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    Moderator The Monk's Avatar
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    Default Re: Rebuilding Royal Enfield Bullet 1996 cast iron

    Rebuild Thread Approved
    Biking is not about what you have between your legs, its all about how well you use it!!!!!!!

    Give your details here if you want to help your fellow xBhpian stranded in your city

    Touring Blog: Cycling in Mongolia!

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    Addicted davidlivi's Avatar
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    Default Re: Rebuilding Royal Enfield Bullet 1996 cast iron

    Thanks for the quick approval, Monk

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    Default Re: Rebuilding Royal Enfield Bullet 1996 cast iron

    Wow! Looking forward to this one! Do post some pictures of the bike taken before restoration!
    davidlivi likes this.

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    Default Re: Rebuilding Royal Enfield Bullet 1996 cast iron

    Have you done the restoration all by yourself right from engine rebuild to cosmetics?
    If yes, I'd like to see your posts like a workshop manual style. This will certainly help fellow enthusiasts to refer.

    Looking forward to details and pictures :-)
    davidlivi likes this.
    My DIY(s) - Sprocket bearing change | Paint job | Custom speedo dial

    Getting angry at somebody is the same as getting angry with a bike that just won't go. You should stop and start thinking.
    A good mechanic will let you watch even without charging you for it. | Riding faster than everyone else only guarantees youll ride alone.

    It is funny to know that we've been imitated and copied so well
    and surprising when we notice our mistakes are copied as well.

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    Addicted davidlivi's Avatar
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    Default Re: Rebuilding Royal Enfield Bullet 1996 cast iron

    Quote Originally Posted by sanjaynk15 View Post
    Wow! Looking forward to this one! Do post some pictures of the bike taken before restoration!
    This picture has been taken very long back
    Attached Images Attached Images  

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    Addicted davidlivi's Avatar
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    Default Re: Rebuilding Royal Enfield Bullet 1996 cast iron

    Quote Originally Posted by petrolhead_chn View Post
    Have you done the restoration all by yourself right from engine rebuild to cosmetics?
    If yes, I'd like to see your posts like a workshop manual style. This will certainly help fellow enthusiasts to refer.

    Looking forward to details and pictures :-)
    Restoration will be done by me. So will try to upload all the work as much as possible.

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    Addicted davidlivi's Avatar
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    Default Re: Rebuilding Royal Enfield Bullet 1996 cast iron

    Engine case is buffed and other plated parts
    Attached Images Attached Images     

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    Addicted davidlivi's Avatar
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    Default Re: Rebuilding Royal Enfield Bullet 1996 cast iron

    Lot of engine oil was thrown out of breather tube during riding. One of the problem was leakage in between timing shaft and crank case. It was rectified by fixing a bush in crank case.
    Attached Images Attached Images  

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    Addicted davidlivi's Avatar
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    Default Re: Rebuilding Royal Enfield Bullet 1996 cast iron

    Few fins in the cylinder head and barrel were broken. Small aluminium pieces matching the broken fins were made and aluminium welded.
    Attached Images Attached Images    
    Legend Racer likes this.

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