[siddharth_menon]

I was on my way to Pune and this happened


A loud noise followed by gear grinding sound.


My friends helped me & we pushed it to the nearest mechanic, convinced him to open & check. Thank god I had RE mechanic's number, he guided the overall operation.

When we opened the case, look what we found.


The screw that you see on the left hand side magically opened & some how got in between the clutch drum & case. My bad luck?

A closer look


Managed to glue things with fevi-bond & took my leaking bike to Pune & back to Mumbai. Yes had to carry extra oil too.

How did that screw come out?

1. Well my sprag clutch was already damaged 2-3 thousand kms before. This sprag clutch was replaced under warranty before but still faulty. I speculate its happening because of faulty decomp. Now not sure but can a faulty sprag clutch have caused it to spin out?
2. Other assumption is that mechanic did not tighten it after replacing sprag clutch (under warranty) which was done long back.

Estimated cost for fix ?
18k approx to change it with new LHS engine case. This can be fixed by welding also, i am still awaiting quotation. Any suggested estimates?

My Conclusion
I feel this is a design flaw & RE should address such cases. In fact I am disappointed that these guys don't offer engine warranty beyond 1yr. And of course I don't have 18k to fix.


Is there cheaper permanent fixed?
Awaiting your suggestions. I am broke

Here some pics for your eyes
Bike and Me - a set on Flickr

Cheers,
Siddharth

[Leepower]

Ouch.... this nearly happened to me. My 78 bulls alternators rotor has cracked. Luckily it didn't tear into the gear assembly... I didn't know that it had happened and during a routine servicing my mech found it and replaced it. Thank god!!!
I think any fragment of metal in a running motor, be it a screw or a nut, acts like a shrapnel from a grenade and can tear into almost anything.
Is this bike under warrantee??? If you have reached Pune, just take this bike to Kunal bike works in Vimannagar. He is a Bullet doctor. PM me, I can get you his contact details.

[siddharth_menon]

Originally Posted by Leepower

Is this bike under warrantee??? If you have reached Pune, just take this bike to Kunal bike works in Vimannagar. He is a Bullet doctor. PM me, I can get you his contact details.

Your lucky

My bike is out of warranty, so its all on me to get it fixed. This happened 2 weeks back. I was on my way to Pune, now I am back to Mumbai. Gave to Nerul Service station last week.

They diagnosed it & told me a replacement would cost ~18k. Alternatively a cheaper option would be to get it welded, since it cracked along the screw hole it can be little tricky.

[shivshanker]

Hello Siddharth,

If you have a service record during warranty period, this has to be contested. Such a break down cannot be attributed to wear and tear due to regular use.

This looks more like somebody tried to fit in a bolt which had a bigger pitch than the original one.. as the casing and the threads show like they have imploded.

Check out the bolt please.

Cheers

Shivshanker

[siddharth_menon]

Originally Posted by shivshanker

Hello Siddharth,

This looks more like somebody tried to fit in a bolt which had a bigger pitch than the original one.. as the casing and the threads show like they have imploded.

Check out the bolt please.

Cheers

Shivshanker

The bolt head actually got stuck between the clutch drum & the bottom of the case & that is when it cracked. It made a loud sound. There after it was constantly touching the drum with a grinding sound.

I checked the bolt & it looks perfectly fine.


I will try with RE, since the part was replaced in warranty they should have it in record. Nerul Service station was a complete mess back then, little better now.

18k is a big price to pay for their carelessness.

[anjan_c2007]

Firstly, I am sorry and sad to read about something that happened to a new bike just out of warranty.
Secondly, I believe Murphy's Law always applies to us most of the times.The more we love machines the more these laws apply and sometimes tear us apart.
Thirdly, I believe welding the unit there (aluminum welding is also done) may not be a permanent cure for the malady as gear oil leak anytime later, due to pressure build-up or creation due to any reason within the chamber (or even outside the chamber due to any minor hit during handling) will again invoke Murphy's law and gear oil leak will be the immediate result.
So it would be best to go for aluminum welding immediately and handle the machine very, very carefully for a while.
Thereafter, please try for some accident damaged or salvaged Bullet, whose LHS engine chamber/case is exactly similar to yours but is intact. You may get such a spare for a bargain. Usually such damaged machines are with the dealers for insurance claims.Since you are in Mumbai and Pune too, its easier to keep an eye on dealers who will by chance have such a donor machine.
Finally welding and temporary touch-ups are no solution. The chamber has to be changed (new or old) to be hassle free.

[Rennjit]

Originally Posted by shivshanker

... If you have a service record during warranty period, this has to be contested. Such a break down cannot be attributed to wear and tear due to regular use. ...

Correct, you should raise this asap to resp area/regional service heads and flag this as faulty workmanship & of sheer negligence. Ask him to explain why the nut came off. Ask for a free replacement, atleast you'll get a good discount or waived off service labor.
Its ok to go welding but how good it'll turn out depends on direct involvement- locating a shop & deciding repair method they suggest is good enough.

[bblost]

Raise this up with the Royal Enfield. Get them involved as the cover was opened and fixed by them. This shoddy workmanship is very bad.

Also email them this thread. Let them understand that they have a chance to correct a bad mistake by their workmen and earn a good name for themselves.

I don't think welding is a good idea.

[Prithvi]

More and more problems cropping up on new RE CLassiks, come on RE wake up!

Customers are paying a huge amount and also waiting in line for these bikes. Buckle up and give them better quality.

[siddharth_menon]

Originally Posted by anjan_c2007

Secondly, I believe Murphy's Law always applies to us most of the times.The more we love machines the more these laws apply and sometimes tear us apart.

I agree with you

Originally Posted by Rennjit

Correct, you should raise this asap to resp area/regional service heads and flag this as faulty workmanship & of sheer negligence. Ask him to explain why the nut came off.

Originally Posted by bblost

Raise this up with the Royal Enfield. Get them involved as the cover was opened and fixed by them. This shoddy workmanship is very bad.

^^ You guys are right, 18k is high price to pay for carelessness. I am already on it, RE is not known for good service so not sure how this will go.

Welding is always a temp fix & plus no piece of mind, may be 2nd hand case if I get lucky is a better solution.


Btw this side of the case has engine number printed. If I change then I will have to update records with RTO & insurance?

[Gordon]

I'm not quite surprised with this. I've always thought TVS was the worst in service, but it is true that RE is really pathetic in service and quality of mechanical/electrical parts. I say this although I am planning on buying a Classic 500, knowing its not worth 1.5L

First things first, get the matter up with the authorities. The fact that you opened up the bike at a local mechanic may cause some complication.

Anyways, I guess you can try sourcing a used part OR welding the area would definitely be the cheapest option.

Since you did get a quotation, could you post the break up of the parts for which he quoted Rs 18k. Sound highly unlikely for just the LHS casing.

[ArizonaJim]

The damaged part appears to me to be the left engine crankcase, not the side cover.

That broken boss is what the sidecover bolt screws into and although the side cover may be damaged and require replacing as well, a side cover is considerably cheaper than half of an engine block.

As for a weld repair, yes, it can be done but only an experienced welder should be allowed to attempt it.

Because he will be welding on a part with a number of precision bores machined into it, there is a good likelihood of the part being irreparably damaged.
Failing to use proper heat sinks and other protection to prevent overheating the housing could easily damage the alignment and spacing of the crankshaft and gear shafts which align with the other side of the crank case.

From what I see, there is no doubt that the damage was caused by a loose fastener that became lodged between the clutch housing and the boss.
The only explanation for a loose fastener in this area is negligence on the part of the mechanic.
If the engine had been repaired by a Royal Enfield authorized shop I feel it is their duty to repair the damaged case(s).

[pawan_pullarwar]

Every time I think of buying Royal Enfield 500 Classic and I come across thread where Enfield issues are reported. Even I am scared of buying used. I feel the problem with there assembly line, Royal Enfield must be using old days equipment for assembly.

I think it is better to ask Royal Enfield to fix this issue, take this up with top management. Randhwa must be knowing someone from Royal Enfield with whom you can take up this issue.

[shivshanker]

@Pawan. .with RE it the "getting the hands dirty" that is the issue. Once the initial run in period happens, MOST of the problems are ironed out, except for workmanship issues like this.

But even after the run in period . .it is the getting your hands dirty which is the fun part.

Some of the hard core RE fans I know, spend at least one or two evenings in a week with their favorite road side mechanic for a cup of cutting chai and a smoke.

Punch line,

This is not a fill it forget it bike. it is a passion which grows on you.

[siddharth_menon]

Originally Posted by ArizonaJim

The damaged part appears to me to be the left engine crankcase, not the side cover.


The only explanation for a loose fastener in this area is negligence on the part of the mechanic.
If the engine had been repaired by a Royal Enfield authorized shop I feel it is their duty to repair the damaged case(s).

Yes that is the crank case with engine number printed. However the cover is absolutely fine, no sign of damage.

I have my same concerns about welding. Bike is still at RE service station & today they might try their lucky with welding.

Originally Posted by pawan_pullarwar

Every time I think of buying Royal Enfield 500 Classic and I come across thread where Enfield issues are reported.

To be very frank I was really confident about my engine. Actually the new engines sp EFI I very reliable, what is not reliable is the after service. I am really happy to know RE has made so many improvement since my version.

Originally Posted by shivshanker

Punch line,

This is not a fill it forget it bike. it is a passion which grows on you.

Okay so far I have send a mail to Vikram Vaidyanathan, thanks shivshanker for contact. But no reply.

Then I tweeted this link to @RoyalEnfield & they quickly responded with this https://twitter.com/#!/royalenfield/...60939227521024

"@BuddhaSource send a mail to customerservice@royalenfield.com address it to Mr Rajkumar"
"@BuddhaSource else send a mail to twitter@royalenfield.com and we shall route it to the concerned person!"

It sounds good but lets hope. I am still waiting for an official reply.