[masterChief007]

I am planning to restore/resurrect my old CI bullet, which is lying in the parking unused and uncared for past 4-5 years. I would appreciate any suggestions regarding what all work should I concentrate on such a bike.

Background:
Owning a bullet cast iron can be a pain especially if you get a lemon which has it's engine siezed at 12000km mark at 80kmph on highway, that too just after a week it got serviced from a Authorized service center (Sampangi Rama Nagar, Bengaluru). But as you get addicted to the quirkiness of the motorcycle, you find switching to any other bike difficult (even within the RE stable).

So even when it ditched me on the highway, I kept it running till 24-25000 km during which I learnt a few of the jobs like tappet adjustment, carb setting for air-fuel mixture, and the life-line of clutch cable replacement etc it still kept giving me troubles here and there, shutting off in the middle of traffic and what not.

So finally 4-5 years back I had enough and one day when it was again throwing tantrums, I lost the patience and moved over to my car as the primary mover. Since then it is lying idle in the parking and collecting dust.

Recently I was contemplating regarding a new motorcycle for my regular runs (pun intended), which I would take for my morning runs, gym and light groceries and occasionally on long rides (mostly solo). And then suddenly my heart strings got plucked again for this old love.

So I decided to give this love one last sincere try before I just turn my back on it, and get a new motorcycle. Basically I want to get it restored for the essential bits so that I can determine whether I would keep it for the long run (registration expires in May 2023).

My planned restoration:
1. buffing and cleaning of timing, clutch covers and complete servicing
2. de-rusting and cleaning the petrol tank
3. cleaning/replacement of the carb and float
4. getting the engine block opened/decarbonated and if required re-boring (it has already been re-bored after the siezure at 12000k mark)
5. replace spark plug
6. change all rubber parts, including tyres
7. replacing all cables
8. replacing all electrical wirings
9. new battery
10. get new tyres and tubes
11. get the rim/spoke adjusted/balanced/replaced as its lying in dead storage for so long
12. figure out issues with the alternator as the charging used to be very bad (headlight would be dim, and the horn would be like a lambs bleating)
13. get the gas shockers filled again with gas
14. and of course all oils and grease replaced engine/clutch
15. replace chain and sprocket setup (it is busted due to backlash)
16. Replace air-filter
17. Brake shoes

Please advice regarding the above activity so that I can use the vehicle for coming 2-3 years as a beginning and let me know if I need to add/remove any activity from the above list. Also a rough estimate that I may need to incur.

Would love to write a travelogue with my bullet in coming months

[masterChief007]

Once upon a time:

[tilt]

I had two Bullets - a 1967 army bike and a brand new 1984 one I bought new. The '67 was amazingly good but the '84 was a love-hate relationship. I hated the bike with a passion when it was with me and loved it and missed it when it was in the shop (which was for at least 75% of the time I owned it).

That '84 soured my opinion of Enfield bikes so badly that even today there's nothing RE can do (or anyone here [including current owners] can demonstrate) to change my mind.

Cheers

[masterChief007]

Originally Posted by tilt

That '84 soured my opinion of Enfield bikes so badly that even today there's nothing RE can do

Sorry that you had a bad experience. Maybe the 67' make was properly fixed by the Army mechanics to a proper bike before you got it, but the 84' one didn't get the same treatment from the service centers.

I had bad experience with the "Authorized" service centers of RE. Quality control while production and addressing issue during their servicing used to be non-existent with them. I hope both these aspects have been largely addressed for their new gen bikes.

Somehow I feel that compared to cars, bikes develop more issues per km travelled (across all makes). I don't know why this is so, maybe I am wrong but that's what I have felt.

[tharian]

If the bike has been lying idle for just 4-5 years, you only have to give it a general full service.

- tank cleaning
- carb cleaning
- Spark plug clean/ replace
- ignition points cleaning
- new battery
- tyre if you are planning to do rides, it's better to replace.
- check wheel bearings
- check air filter & hoses
- check chain/ sprocket
- the gas shocks cannot be recharged, it needs to be replaced. But the Standard 350's came with oil ones if you want the original set up.
- wheel trewing if required
- don't open the engine till required
- wiring and cables can be checked down the line. The cables needs to be oiled and they will be fine. They don't keep snapping like the older bikes.
- if the battery is not charging properly, you will have starting trouble, so that has to be checked for sure.

These old bikes are quite basic and simple to fix. These models have a good value as well even now. I am guessing this is a 2005-08 model?

[GTO]

Not a motorcycle guy, but one thing I can tell you is = resurrection / restoration budget is always limited . It's tempting to go the other way, but always prioritize the money & effort on mechanicals over aesthetics. A well-running machine has a greater feel good factor than one that just looks beautiful.

Good luck with bringing her back to top form .

[masterChief007]

Originally Posted by tharian

I
- ignition points cleaning
- the gas shocks cannot be recharged, it needs to be replaced. But the Standard 350's came with oil ones if you want the original set up.
- don't open the engine till required
- wiring and cables can be checked down the line. The cables needs to be oiled and they will be fine. They don't keep snapping like the older bikes.

I am guessing this is a 2005-08 model?

Thanks Tharian, I have added the CB point cleaning and adjustment (how did i forget to list this !). I had replaced with gas shocks from the original, maybe I will go back to the regular ones then.

Regarding engine block, don't you think the engine o ring gaskets might have gone bad over the years and might need replacement? Also wanted to check if there would have been any scoring of the cylinders as a side activity.

I want to be safe regarded the wiring/cable snapping, will see what the mechanics suggest about it. But definitely the alternator needs some work, it had charging issues earlier.

This is 2008 model (one of the last CI's to be built). Gratefully it never "marked" its territory, so that was an improvement.

Originally Posted by GTO

resurrection / restoration budget is always limited . It's tempting to go the other way, but always prioritize the money & effort on mechanicals over aesthetics.

Thanks GTO, yes I am just going for the mechanicals only, I want to retain the original look, so not going to tinker with seating, lighting or any non-essential paint-job. First have to make it run a bit and see how it behaves. And then only it will make sense to invest more on it.

[tharian]

Originally Posted by masterChief007

Regarding engine block, don't you think the engine o ring gaskets might have gone bad over the years and might need replacement? Also wanted to check if there would have been any scoring of the cylinders as a side activity.

I want to be safe regarded the wiring/cable snapping, will see what the mechanics suggest about it. But definitely the alternator needs some work, it had charging issues earlier.

If the gaskets are gone bad, oil will start leaking which can be seen on the fins and the engine will loose compression. Unless the oil is dripping because of that, it doesn't have to be replaced. If the cylinder is scored badly, the engine will be noisy. The piston movements that is, not the tappets or any other sound.

Alternator on a low run bike will mostly not be the issue, maybe you can check the pick up coil inside the clutch case as well as regulator/rectifier unit.

[keroo1099]

What!!! A CI 350 that doesn't mark it's territory can't be a bullet

I have a 82 model that's spent it's fair share with some mechanic or the other but like you can't seem to let it go. I did sell it when I went to the US, but my wife missed it so much she bought it back, sigh.

Like you, I have learnt to set the tappets, advance/retard, point gap, carb tuning, etc. which in a way makes it fun to hang on to it but I'm finding it harder and harder to get parts for these old machines. I have done a few mods on mine, a 5 plate clutch which prevents the clutch slippage and a 24mm Mikuni flatslide carb for better response as I only use the bike in the city.

I just got the fitness done on mine so it's good for the next 5 years.

Good luck restoring yours.

[masterChief007]

Originally Posted by tharian

Alternator on a low run bike will mostly not be the issue, maybe you can check the pick up coil inside the clutch case as well as regulator/rectifier unit.

Ok I will get the coil and the rectifier checked too, will have to write all these suggestions down for my garage visit now !

Originally Posted by keroo1099

What!!! A CI 350 that doesn't mark it's territory can't be a bullet

I just got the fitness done on mine so it's good for the next 5 years.

Good luck restoring yours.

Haha, you are right, but maybe it was sitting in place so much that it's territory didn't need marking Congrats on your registration renewal, Actually I wanted to see in the next few months on how it serves me, if it doesn't behave I would have to get a new motorcycle, but if it runs fine I too will renew the registration. Keeping fingers crossed !!

[anjan_c2007]

The resurrection and restoration jobs are a welcome decision. Firstly, please spend enough time to locate a very skilled and reliable mechanic /workshop which exclusively does such Bullet jobs. Bullet workshops generally do not take liberties repairing other brands but are RE Bullet specific. They are true blue "Bullet Doctors." You can contact old CI Bullet owners for their inputs about the mechanic /workshop.

Secondly and lastly, apart from the usual 'to do' jobs for prolonged non-use, after zeroing upon a good workshop, also please take suggestions from the mechanic, who after thoroughly checking can recommend more repairs/replacements.

[masterChief007]

Originally Posted by anjan_c2007

Secondly and lastly, apart from the usual 'to do' jobs for prolonged non-use, after zeroing upon a good workshop, also please take suggestions from the mechanic, who after thoroughly checking can recommend more repairs/replacements.

Yes I am going to list them my minimum to-do list, on top of that if they see some real impending doom, I will get that one fixed/replaced too. In case the vehicle gives me 3-4 years more, I am golden.

Just for jokes, to maintain a CI bullet, you need a spare bike/scooty (the one with which you need to bring in spares/parts/mechanics from time to time)

[tharian]

Originally Posted by masterChief007

Just for jokes, to maintain a CI bullet, you need a spare bike/scooty (the one with which you need to bring in spares/parts/mechanics from time to time)

On a CI Bullet, which I am sure you know well too, unlike other bikes wherein the maintenance starts as the bike gets older or has run quite a bit. On a CI engine, the first few years are the maintenance period in which you baby the engine and do the periodical engine oil/clutch oil change, set the tappets, let the engine warm up before riding, etc, and the bike lasts you for a long time after that.

The post-2002 CI bikes were quite reliable too unlike the ones before that.
My city run-around bike is a 350 CI Electra that is over 20 years old and still running strong. Contrary to popular belief, it has never broken down or given me major issues.

[nettooran]

Been there done that .. multiple times. Your budget is in fact unlimited. but a paintjob, buffing/crome plating, and the mechanical work is going to put you back by 50k minimum. But it is definitely worth it. The CI bullet never loses it charm and can be built over and over again and it would look beautiful. There are plenty of great workshope in Kerala that does this. Not sure out of this state though

[Guru_Shikhar]

Hi Masterchief007,

Great to know you have an iconic bike with you and you are willing to restore it. As GTO mentioned; be ready with a good budget.

I would like to suggest you a couple of things-
1. Change all gaskets
2. Check out the Carberry vibration reduction plate. The online price is 3299/-. This will help reduce the vibrations in the band of 60-90 km speeds.
(Pl confirm if this is suitable for CI engine)

There are many many accessories for the CI engine bullets. I had a 2008 model while my brother had a 2003. Both sold the bikes for reason of constant garage visits and my Dad did not allow to add Himalayans with these bikes in parking. Got 2 Himalayans.
Life is quite sorted then after.

Keep updating the thread.

Cheers.