RE Classic 500 - A screw that ripped my engine case

siddharth_menon · 10th December 2011, 14:34

Update :
1. I got a call from RE Chennai, they took my engine number details etc & said they will get back to me.

2. Mail response too, with the right contact person for this problem. A ticket is also generated :P

3. I met Sameer who runs the Authorized Service Station at Nerul, Mumbai. He had also taken some action & forwarded pictures to RE. Feels bad to see my engine completely dismantled.

A bitter discovery - Could happen to anyone
I am not the 1st guy with this bolt problem, but one of the cases lead to case crack. There is a design flaw like I mentioned before. The rotary direction of the crank & the bolt should have been opposite, such that more the engine spins the bolts get more tightened. As of now the tread is other way around & thus results in loosing of bolt very early. RE has addressed this flaw & released a new bolt for engines after July 2011, I am not sure if the thread has been reversed in this revision.

My advice to all the RE owners who got their bikes before July 11, get this bolt inspected & changed with new one.

As for my case I think its going positive. There is a "good chance" that RE would replace the parts free of cost, no official word yet. To be frank I am really overwhelmed by the response from RE, I am surprised. In just 2 days I can see some progress, but lets not get carried away

Thanks everyone. Finally a reason to smile.

Rennjit · 10th December 2011, 20:38

Quote:

Originally Posted by siddharth_menon

... The rotary direction of the crank & the bolt should have been opposite, such that more the engine spins the bolts get more tightened. As of now the tread is other way around & thus results in loosing of bolt very early. ...

IF ^ is exact, i got no words to say...(gulp!)
Ideally the fastener there would do with regular RH thread & i don't think they have put LH thread. The later changes may be in thread spec or an added lock tab provision. Anyways good to know that RE admits the issue, tweeting up was a nice move.

sriku · 19th December 2011, 12:33

Quote:

Originally Posted by siddharth_menon

Update :

My advice to all the RE owners who got their bikes before July 11, get this bolt inspected & changed with new one.

As for my case I think its going positive. There is a "good chance" that RE would replace the parts free of cost, no official word yet. To be frank I am really overwhelmed by the response from RE, I am surprised. In just 2 days I can see some progress, but lets not get carried away

Thanks everyone. Finally a reason to smile.

Glad to see RE taking your case seriously and interacting positively.
Thanks for giving us the update about the design issue, this could be one of the upgrades they slipped into the Desert Storm as well, along with the front fork re-design. Heartening to see they are making some upgrades. Wonder what other changes they have put into these bikes since July 2011.

hollywoodhogan · 20th December 2011, 09:57

if you had not tweeted this issue am sure you would have to pay for it. hope you get the waranty for this damage. wonder how may bikes that are out of warranty will suffer this fate?

trinadha · 20th December 2011, 18:54

sorry to know about the damage
good to hear the response from REnfield,should wait for the problem to be fixed;I was shocked and this issue is scaring me about buying a RE,hoping to see the problem being rectified.

siddharth_menon · 16th January 2012, 19:08

RE Nerul service station has my Bike since 27th Nov and today its 16th Jan 2012. Hopefully by tomorrow I should be getting my bike back.

A recap of damage done because of one bolt

Sprag clutch - caused possibly due to loose nut & slippage
Found a spacer / washer broken behind the sprag clutch. This took lot of time for shipment as RE chennai spares was closed for holidays.
Engine LHS case
Hopefully a new & improved nut

I am lucky RE has replaced my LHS engine case with new one, this costs nearly 20k. They are not convinced that the sprag clutch was damaged because of this nut so no replacement there costs 4k. Labour & rest of the parts on me.

Will share the break down of cost once I get my bike back. Waiting to ride since long time

Chanderjeet · 16th January 2012, 19:57

Editing :

Good to see it turned out OK. Safe riding.

siddharth_menon · 19th January 2012, 09:56

Okay good news & the bad news.

Good news

Bike is finally ready

Bad news

Total bill Rs 13,600/-
I have not seen the bill myself but this is what was conveyed over the phone.
This includes (guessing)
Engine Case - replaced by RE for free, other wise would have costed 18k more.
Labour
Gaskets
Sprag Clutch - 4k (No replacement here)
New bolt - he was not sure but if its new design then it should be little longer
Oil & filter*
Sprocket kit* - 1.8k
Handle Cone* - Not sure changed but lets assume
Fuel pump tube*

*(Not related to this incident)

Please advice, if this looks fine.

I don't want to rant so much but one design flaw has costed me this, some say its expensive. C500 is my 1st bike so I am not sure if this is okay, I don't know how other manufactures sort these case either.

acroback · 19th January 2012, 11:01

Hopeless QC RE has.
Though I have my sight on 350 Classic, such experiences force me to rethink my decision.

I wish someone could slap a consumer case on RE and put some sense into them.

Sid, I hope you won't have any such incident again.
But to naked eye 9600(13.6- 4k for sprag clutch) looks very high.

What on earth are they putting in your CL5? The bill borders close to paid service costs of some sedans lol.

Also, so what exactly are morons at RE including in warranty???

siddharth_menon · 19th January 2012, 11:57

lol I have Ford Feista and recently got some major work done which costed just about 15k. Both front break assembly & discs, ac condenser, synthetic oils, belts etc. Mind you Ford are known for expensive service.

Quote:

Originally Posted by acroback

Hopeless QC RE has.
Sid, I hope you won't have any such incident again.
But to naked eye 9600(13.6- 4k for sprag clutch) looks very high.

What on earth are they putting in your CL5? The bill borders close to paid service costs of some sedans lol.

Also, so what exactly are morons at RE including in warranty???

Well there are few components that was not part of the problem like mentioned in the list which approx to total 3200.

Bike is now 1.5yrs old. They had changed the sprag clutch during warranty and hence I was able to contest for poor service. I got the replacement because there was this design flaw (lol they will not admit it officially).

Btw I am just on my way to check the bill to see what they have charged.

Also good news is that they have made lot of design improvement in last 2yrs after launch. I am like the early beta users :P

voodoochild · 19th January 2012, 13:08

Discounting the costs of sprag clutch (6k) and the miscellany (3.2k you say), it looks like either some pretty expensive labour and gaskets, or that's one heck of an expensive "new design" bolt!! Any further details on that bill?

Cheers,
Rahul

Gansan · 19th January 2012, 13:39

Ouch! That is bad. RE should have done everything free of cost. And one more thing. Check the milling at the tip of the shaft where this nut is mounted. If that is worn out (can happen when the nut is loose), same problem can haunt you again.

Reminds me of a similar problem in my KB 100 during '91. A similar nut fastening a sprocket to the "Final output shaft" had worked loose. There was no other damage but the milling at the shaft's tip was worn-out, so the nut could not be tightened. The spare shaft was not available anywhere. Repeated entreaties to Bajaj fell on deaf ears.

Finally the engine was dismantled by an experienced mechanic, the shaft was re-threaded in a lathe and the engine reassembled again! I have not touched a Bajaj product since then, not even with a barge pole!

hollywoodhogan · 19th January 2012, 22:58

hey, all the stuff that has failed is "consequential damage" and so you do not have to pay for it. pay only for the oil and gaskets and rubber items. as for the rest, do not accept to pay. if you are up to it, refuse and if they act tough, get a lawyer to send them a notice. demand an entire set of the copies of the job cards.

or bluntly warn them that if they do not accept your terms, that you will blog and blog and blog all over the net in all forums about their stingy and pathetic way enfield treats their customers. and when you say it, MEAN IT MAN! screw them!

DO NOT GIVE IN. am sure that there are other similar cases (crankcases!!)all over india that your lawyer can quote.

scan the bill or estimate copy and post it please! and go the company website and post your grievances on shaji, venki and sid lal blog. basically make a "pain in the ***" of yourself and that is the only way they will listen to you.

black12rr · 19th January 2012, 23:19

Quote:

Originally Posted by siddharth_menon

Also good news is that they have made lot of design improvement in last 2yrs after launch. I am like the early beta users :P

wish it was that simple ,you could uninstall beta version and install RTW verison . :( .

But 13 k Rupees for no fault of yours and a screwed up bike trip is a no no ..

.

RE should foot the bill . Did they take your permission before replacing other parts apart from damaged parts ?

siddharth_menon · 20th January 2012, 10:11

Here is the rough break up
(Tax exclusive )

Cost for fixing the Bolt problem Total Rs.6931 + Rs.2007

Engine overhauling - Rs.3500
Sprag clutch - Rs.3431
Consumables below
Gasket & other stuff - Rs.1227
Oil + filter - Rs.780

Other unrelated spares & costs

Rear Break shoes with fitting - Rs.324
Auto D comp can gear - Rs.1837
Chain & Sporket - Rs.1335
Air filter - Rs.145
Washing - Rs.100
Vat - Rs.915

To sum it up my actual unnecessary damage is about 7k.
Since my case was registered at RE directly Priyank (TSM - Mumbai) called up for feedback and confirmation. He said he was not aware of the sprag clutch problem & will look into it.

However I feel its not just design quality that needs to be blamed but the service quality. RE has little control over quality of service. Every time I give my bike for service I feel its degraded. Careless scratches, cable not connected, screws missing etc are common.

I was shocked to find 2 screws missing in RHS cover & the main case, I am going back to service station again today. I think the bolt problem would have not happened in the 1st place if the mechanic who fixed my sprag clutch 7 months before did it right. Yesterday after delivery I can hear a whooshing sound (like metal rubbing light) when the engine heats up, I told the service manager, he said since all parts are in new case it will take some time to tune up. Hmm. Some how its hard to trust the workmanship.

10th December 2011, 14:34	#16
siddharth_menon BHPian Join Date: Dec 2007 Location: Mumbai Posts: 64 Thanked: 6 Times	Re: RE Classic 500 - A screw that ripped my engine case Update : 1. I got a call from RE Chennai, they took my engine number details etc & said they will get back to me. 2. Mail response too, with the right contact person for this problem. A ticket is also generated :P 3. I met Sameer who runs the Authorized Service Station at Nerul, Mumbai. He had also taken some action & forwarded pictures to RE. Feels bad to see my engine completely dismantled. A bitter discovery - Could happen to anyone I am not the 1st guy with this bolt problem, but one of the cases lead to case crack. There is a design flaw like I mentioned before. The rotary direction of the crank & the bolt should have been opposite, such that more the engine spins the bolts get more tightened. As of now the tread is other way around & thus results in loosing of bolt very early. RE has addressed this flaw & released a new bolt for engines after July 2011, I am not sure if the thread has been reversed in this revision. My advice to all the RE owners who got their bikes before July 11, get this bolt inspected & changed with new one. As for my case I think its going positive. There is a "good chance" that RE would replace the parts free of cost, no official word yet. To be frank I am really overwhelmed by the response from RE, I am surprised. In just 2 days I can see some progress, but lets not get carried away Thanks everyone. Finally a reason to smile. Last edited by siddharth_menon : 10th December 2011 at 14:37.
	() Thanks

20th December 2011, 09:57	#19
hollywoodhogan BHPian Join Date: Jul 2007 Location: bangalore Posts: 423 Thanked: 15 Times	Re: RE Classic 500 - A screw that ripped my engine case if you had not tweeted this issue am sure you would have to pay for it. hope you get the waranty for this damage. wonder how may bikes that are out of warranty will suffer this fate?
	() Thanks

20th December 2011, 18:54	#20
trinadha BHPian Join Date: Aug 2005 Location: HYDERABAD Posts: 244 Thanked: 22 Times	Re: RE Classic 500 - A screw that ripped my engine case sorry to know about the damage good to hear the response from REnfield,should wait for the problem to be fixed;I was shocked and this issue is scaring me about buying a RE,hoping to see the problem being rectified.
	() Thanks

16th January 2012, 19:08	#21
siddharth_menon BHPian Join Date: Dec 2007 Location: Mumbai Posts: 64 Thanked: 6 Times	Re: RE Classic 500 - A screw that ripped my engine case RE Nerul service station has my Bike since 27th Nov and today its 16th Jan 2012. Hopefully by tomorrow I should be getting my bike back. A recap of damage done because of one bolt Sprag clutch - caused possibly due to loose nut & slippage Found a spacer / washer broken behind the sprag clutch. This took lot of time for shipment as RE chennai spares was closed for holidays. Engine LHS case Hopefully a new & improved nut I am lucky RE has replaced my LHS engine case with new one, this costs nearly 20k. They are not convinced that the sprag clutch was damaged because of this nut so no replacement there costs 4k. Labour & rest of the parts on me. Will share the break down of cost once I get my bike back. Waiting to ride since long time
	() Thanks

16th January 2012, 19:57	#22
Chanderjeet Awaiting Email Confirmation Join Date: Jul 2007 Location: Delhi Posts: 105 Thanked: 126 Times	Re: RE Classic 500 - A screw that ripped my engine case Editing : Good to see it turned out OK. Safe riding. Last edited by Chanderjeet : 16th January 2012 at 19:58.
	() Thanks

19th January 2012, 09:56	#23
siddharth_menon BHPian Join Date: Dec 2007 Location: Mumbai Posts: 64 Thanked: 6 Times	Re: RE Classic 500 - A screw that ripped my engine case Okay good news & the bad news. Good news Bike is finally ready Bad news Total bill Rs 13,600/- I have not seen the bill myself but this is what was conveyed over the phone. This includes (guessing) Engine Case - replaced by RE for free, other wise would have costed 18k more. Labour Gaskets Sprag Clutch - 4k (No replacement here) New bolt - he was not sure but if its new design then it should be little longer Oil & filter* Sprocket kit* - 1.8k Handle Cone* - Not sure changed but lets assume Fuel pump tube* (Not related to this incident) Please advice, if this looks fine. I don't want to rant so much but one design flaw has costed me this, some say its expensive. C500 is my 1st bike so I am not sure if this is okay, I don't know how other manufactures sort these case either. Last edited by siddharth_menon : 19th January 2012 at 10:10.*
	() Thanks

19th January 2012, 11:01	#24
acroback BHPian Join Date: Aug 2011 Location: CA Posts: 314 Thanked: 127 Times	Re: RE Classic 500 - A screw that ripped my engine case Hopeless QC RE has. Though I have my sight on 350 Classic, such experiences force me to rethink my decision. I wish someone could slap a consumer case on RE and put some sense into them. Sid, I hope you won't have any such incident again. But to naked eye 9600(13.6- 4k for sprag clutch) looks very high. What on earth are they putting in your CL5? The bill borders close to paid service costs of some sedans lol. Also, so what exactly are morons at RE including in warranty???
	() Thanks

19th January 2012, 13:08	#26
voodoochild BHPian Join Date: Mar 2009 Location: Pune, Bangalore Posts: 424 Thanked: 180 Times	Re: RE Classic 500 - A screw that ripped my engine case Discounting the costs of sprag clutch (6k) and the miscellany (3.2k you say), it looks like either some pretty expensive labour and gaskets, or that's one heck of an expensive "new design" bolt!! Any further details on that bill? Cheers, Rahul
	() Thanks

19th January 2012, 13:39	#27
Gansan Senior - BHPian Join Date: May 2009 Location: Chennai Posts: 4,602 Thanked: 5,840 Times	Re: RE Classic 500 - A screw that ripped my engine case Ouch! That is bad. RE should have done everything free of cost. And one more thing. Check the milling at the tip of the shaft where this nut is mounted. If that is worn out (can happen when the nut is loose), same problem can haunt you again. Reminds me of a similar problem in my KB 100 during '91. A similar nut fastening a sprocket to the "Final output shaft" had worked loose. There was no other damage but the milling at the shaft's tip was worn-out, so the nut could not be tightened. The spare shaft was not available anywhere. Repeated entreaties to Bajaj fell on deaf ears. Finally the engine was dismantled by an experienced mechanic, the shaft was re-threaded in a lathe and the engine reassembled again! I have not touched a Bajaj product since then, not even with a barge pole!
	() Thanks

19th January 2012, 22:58	#28
hollywoodhogan BHPian Join Date: Jul 2007 Location: bangalore Posts: 423 Thanked: 15 Times	Re: RE Classic 500 - A screw that ripped my engine case hey, all the stuff that has failed is "consequential damage" and so you do not have to pay for it. pay only for the oil and gaskets and rubber items. as for the rest, do not accept to pay. if you are up to it, refuse and if they act tough, get a lawyer to send them a notice. demand an entire set of the copies of the job cards. or bluntly warn them that if they do not accept your terms, that you will blog and blog and blog all over the net in all forums about their stingy and pathetic way enfield treats their customers. and when you say it, MEAN IT MAN! screw them! DO NOT GIVE IN. am sure that there are other similar cases (crankcases!!)all over india that your lawyer can quote. scan the bill or estimate copy and post it please! and go the company website and post your grievances on shaji, venki and sid lal blog. basically make a "pain in the **" of yourself and that is the only way they will listen to you. Last edited by hollywoodhogan : 19th January 2012 at 23:03.*
	() Thanks

20th January 2012, 10:11	#30
siddharth_menon BHPian Join Date: Dec 2007 Location: Mumbai Posts: 64 Thanked: 6 Times	Re: RE Classic 500 - A screw that ripped my engine case Here is the rough break up (Tax exclusive ) Cost for fixing the Bolt problem Total *Rs.6931* + Rs.2007 Engine overhauling - Rs.3500 Sprag clutch - Rs.3431 Consumables below Gasket & other stuff - Rs.1227 Oil + filter - Rs.780 Other unrelated spares & costs Rear Break shoes with fitting - Rs.324 Auto D comp can gear - Rs.1837 Chain & Sporket - Rs.1335 Air filter - Rs.145 Washing - Rs.100 Vat - Rs.915 To sum it up my actual unnecessary damage is about 7k. Since my case was registered at RE directly Priyank (TSM - Mumbai) called up for feedback and confirmation. He said he was not aware of the sprag clutch problem & will look into it. However I feel its not just design quality that needs to be blamed but the service quality. RE has little control over quality of service. Every time I give my bike for service I feel its degraded. Careless scratches, cable not connected, screws missing etc are common. I was shocked to find 2 screws missing in RHS cover & the main case, I am going back to service station again today. I think the bolt problem would have not happened in the 1st place if the mechanic who fixed my sprag clutch 7 months before did it right. Yesterday after delivery I can hear a whooshing sound (like metal rubbing light) when the engine heats up, I told the service manager, he said since all parts are in new case it will take some time to tune up. Hmm. Some how its hard to trust the workmanship.
	() Thanks