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Friends,
This thread is about the restoration of my colleague's 2008 model Electra 5 speed. He is the second owner since 8 months. It was already driven for 13500 kms while he took it over. He is a sedate driver and hadn't abused any of his drives be it his RX100 / Aviator / Manza. After few weeks of driving, he experienced inconsistent idling and starting issues. Cleaning the carb and changing spark plug did not solve the problem.
Consulting a few Bullet doctors we dared to open the engine head and see what's inside. This is where this thread should actually start. We saw a nice good scratch on the piston & cylinder indicating a seizure somewhere in the past, by the previous owner. Apart from the valve replacement & lapping, the rest was a DIY job in his parking. Gathering time after office hours we were finally able to fire the engine after a week of manhandling the engine parts. New filter, oil & gaskets went in.
Time to run-in the engine. He had been out of station and I was delighted to use the bullet for the next 3 months. I had carefully run-in the engine keeping the speed less than 60kmph and even changed oil & filter after 1500 kms. After around 2000 kms I had to return the bike back to him upon his arrival. A couple of weeks later he had taken it for a highway drive along with friends who were on FZ, Avenger & Duke390. In a rush of adrenalin to catch up the Duke, he had revved it hard and kept pace with 390 till the engine suddenly lost power and coughed. So you bulleteers know what had happened. The engine had seized. Though he held the clutch immediately and the engine was still idling it generated a weird noise while accelerating on load. Now he starts worrying about his bull again.
This time the bullet was taken to a proper doctor who worked on bulls since his childhood. As he found the connecting rod play a little excessive he suggested an engine rebuild. Apart from the engine rebuild he got the itch to convert it to classic 350. So, below is the list of upgrades he has in his mind and has purchased some parts for the same.
1) Fuel sender in the tank + Fuel gauge in place of Ammeter
2) Tachometer in place of the ign switch
3) Twinspark in place of de-compressor + Machismo type De-comp if there is a need. His bike has a self start
4) Mudguards & seats of classic 350
5) Illuminated switch console of P-220 + BCU + Indicator cutoff with sensor + wiring
6) Complete painting + chrome + Aluminium buffing
7) BS29 CV carburetor
8) Oval resonator Classic style
The 2 day weekend gave us the time to sand blast and deposit the chassis frame for powder coating.
Guys, please feel free to post your comments, feedbacks and above all share your experiences if you had already tried out any of the above listed experiments.
Thank you.
This thread is about the restoration of my colleague's 2008 model Electra 5 speed. He is the second owner since 8 months. It was already driven for 13500 kms while he took it over. He is a sedate driver and hadn't abused any of his drives be it his RX100 / Aviator / Manza. After few weeks of driving, he experienced inconsistent idling and starting issues. Cleaning the carb and changing spark plug did not solve the problem.
Consulting a few Bullet doctors we dared to open the engine head and see what's inside. This is where this thread should actually start. We saw a nice good scratch on the piston & cylinder indicating a seizure somewhere in the past, by the previous owner. Apart from the valve replacement & lapping, the rest was a DIY job in his parking. Gathering time after office hours we were finally able to fire the engine after a week of manhandling the engine parts. New filter, oil & gaskets went in.
Time to run-in the engine. He had been out of station and I was delighted to use the bullet for the next 3 months. I had carefully run-in the engine keeping the speed less than 60kmph and even changed oil & filter after 1500 kms. After around 2000 kms I had to return the bike back to him upon his arrival. A couple of weeks later he had taken it for a highway drive along with friends who were on FZ, Avenger & Duke390. In a rush of adrenalin to catch up the Duke, he had revved it hard and kept pace with 390 till the engine suddenly lost power and coughed. So you bulleteers know what had happened. The engine had seized. Though he held the clutch immediately and the engine was still idling it generated a weird noise while accelerating on load. Now he starts worrying about his bull again.
This time the bullet was taken to a proper doctor who worked on bulls since his childhood. As he found the connecting rod play a little excessive he suggested an engine rebuild. Apart from the engine rebuild he got the itch to convert it to classic 350. So, below is the list of upgrades he has in his mind and has purchased some parts for the same.
1) Fuel sender in the tank + Fuel gauge in place of Ammeter
2) Tachometer in place of the ign switch
3) Twinspark in place of de-compressor + Machismo type De-comp if there is a need. His bike has a self start
4) Mudguards & seats of classic 350
5) Illuminated switch console of P-220 + BCU + Indicator cutoff with sensor + wiring
6) Complete painting + chrome + Aluminium buffing
7) BS29 CV carburetor
8) Oval resonator Classic style
The 2 day weekend gave us the time to sand blast and deposit the chassis frame for powder coating.
Guys, please feel free to post your comments, feedbacks and above all share your experiences if you had already tried out any of the above listed experiments.
Thank you.
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