Hitchcocks Forum

Today on a run I had the piston from my 500cc Indian Bullet split in half separating it from the rod. The cylinder head inside looks pretty decent but before this I had a loud clanking noise which I suspected to be the main bear which means I need to crack the case. I've been looking at the 612 kit because it replaces just about everything that I need work on. I have about 4-5 broken fins on my cylinder and bore. Is the kit worth it? Is it a difficult install? I have rebuilt engines but never dealt with having to worry about clearances. Would it just be better to replace the bearing and get the 535 kit? What's your opinions. I'm in the states BTW so I still have to pay VAT correct? Anyone know the turn around time on this? The weather is great and I feel lost without my thumper. Thanks

=Jason-

I don't know if the kit is "worth it", it depends on how happy you are with the way it runs as a 500! Installation isn't difficult (I've read the notes on this,) but needs a bit more care than a standard bike, nothing a competent mechanic can't deal with. You need a 612 Owner to report on performance gain, obviously. Lastly, as a non EU resident you don't pay 20% VAT so the price in the catalogue is what you pay, lucky you!
REgards, Mark

This often happens to to Bullets in Australia.
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I love the idea of the 612cc machine my only reservation would be the smoothness. I have a 350 which is very smooth and whilst sort on bloodthirsty performance you can envisage riding it all day. I know,the 500 isn't considered,to be so sweet running andmimwonder if the 612 might be a bit rough. That said the horse power figures and the power curve does look pretty spectacular and it would be a bundle of fun. Love to hear from someone who actually has one.

I've always wanted to do a 612, never heard anything but praise for them! Owners report a fast but tractable bike results. A 612 + Big Head would really hit the spot!
I live in Guernsey, which is a sort of semi - detached bit of Britain, outside the UK and EU, and we have no VAT here. Our hosts have never charged VAT- - although shipping charges can be a little higher.

Well I'm waiting now on hearing a quote from hitchcock to see how much the total with shipping is going to set me back. Seems like the crank bearing is definitely shot, I can move it side to side till it hits the walls so that can't be good. Don't know how to post a pic but I'll try to so you can see the damage.
=Jason-

I've got a 612,if you're worried about vibs,don't.I also have a 535,original from the factory.The 612 is smoother than it and the original 500 when new.As to worth it who knows,you could fit a new piston to that for much less and be happy again.jack

Logs.

I had a 612 for quite a few years and I thoroughly recommend it.

Performance is far superior to a 500 and vibes are nothing to worry about, personally I thought it smoother than the 500.

Cruising at 70MPH on the motorway is a reality, as is riding around town where it is just as docile as a 500 - and starting is a doddle once you have the technique sorted.

If you are a reasonably proficient home mechanic then doing the conversion is no problem go for it you will NOT be dissapointed.

If you do do it make sure that you take the trouble to run it in properly.

I only sold my 612 to make way for another project.....and I wish I hadn't.

So you tried squirting a drop of oil in the plug hole and still the compression didnt come back. hmmm

Its like trying not to look at a car wreck.. fasinating cant stop looking at the picture.

Is this the common problem of the OEM piston top coming adrift or impact damage?

JB weld and autosol? no not this time...gwilly

Hi Logs,

I had a 2007 Bullet 500 that was converted from new to a 535. My German dealer then had his own 612 which performed very well. After 4 years with the Bullet and wanting more performance, I had the choice of a 612 conversion or going for an EFI. Since I really wanted a 5 speed gearbox and front disc brake, the total extra cost of conversion would have been around GBP 3,500. I decided to go for an EFI and after selling my old Bullet, the EFI cost me an extra 1,400 GB Pounds. The performance is certainly less than a 612, but I can upgrade the exhaust, fit the Big Bore kit and a new Power Commander for about 850 Pounds and get up to 612 performance.
Looking back, I rather wish I had gone down the 612 route. Why? because I would have kept to the original Bullet in principle and would have retained its famous maintainability. The 5 speed and disc brake could have been follow on projects but I would have had the satisfaction of running a hand built motor than was my own work. Good luck with the 612. Cheers TrevorCH