Hitchcocks Forum

Hi. Just cleaning up my 2003 ES 500 Bullet ready for rebuild and I noticed some damage to the edge of the conrod. It seems to have a lot of little scratches all the way down it and a couple of small dings to one edge.
Could this be a problem? I didn't want to split the cases but I`m thinking I may need to polish these marks out to be safe.
Is there a problem with Indian conrods snapping? These marks must have been caused through a clumsy engine build.
I am going to the expense of gas flowing the head and fitting the 535cc alloy barrel. Don`t want to do all that then have the engine blow up!

Dear Ivor,

You can polish the rod and hang it on the wall..

Get the new quality one immediately!

Seppo

Hi Guys--------Ivor...I think you already know the answer to this one ??....As an Ex-RN Marine Engineer the phrase that came to my mind was}------"Spoil the ship for a hap'worth o tar?? "...You're going to be generating more power ABOVE the piston, so why not beef-up the con-rod / bottom end BELOW the piston to handle it ??..............Steel Con-rod with roller big end and an uprated high capacity oil pump to flood those rollers...And while you're at it open up the oilways in the rocker feed as well......Remember that unlike some other Brit bikes the Enfield uses ALL of the scavanged oil to feed the rockers....

Alan R beat me to it, there's an old saying that the best way to finish off a tired bottom end is to fit a tuned top end.

REgards, Mark

Having just recently been "Simonised" on the forum I thought I best give a "Polished" answer from now on !!.... sorry Ivor, let's get back on-thread !!

"Is there a problem with Indian conrods snapping?"



Yes, particularly on the 500 classic Bullet engines, not so common on the 350. A sedately ridden 500 with an **undamaged** original rod might get a high mileage, but to continue using a damaged alloy rod or a highly tuned top end on the original alloy con rod can lead to some expensive misery.



It's not just a problem with Indian 500 Bullets, Redditch 500 Bullets could throw an alloy rod too. Come to think of it, even some steel con rods can snap. I have seen pictures of a couple of older RE singles where this has happened, Leon Novello might be persuaded to re-post his!



A.

file and image uploader

It is know in performance engineering, that a small scratch can develop into a crack which can eventually cause the part to break. Below are some disasters which have befallen owners over the years. It pays to have magnetic plugs fitted wherever you can, as they catch any ferrous metal floating around the oiling system.

Thank you Leon.



As far as I know the Alpha steel rods our hosts sell don't snap, even on race bikes! You should be fine with one of those on a tuned road bike, Ivor.



A.

Clumsy is being kind!
Letting the conrod fall against the crankcase mouth is never an ingredient of engine longevity

I guess I already knew what the answer would be. I`m not intending to tune the motor too much. I`m having the head gas flowed and valve seats re-cut after a conversation with the guy at the Cylinder Head Shop, just to improve things a bit. The 535 conversion is the same price as a 500 new barrel. My iron barrel needs a rebore so I was persuaded to go the alloy barrel route.
My budget wont stretch to a steel conrod so a new alloy one it is. But what do I need to know about the crank pin and big end? Is it an easy job to do? I know the new big end bush will need reaming, which I can probably do, or get done, but does the crank have to balanced after?
Alan R.Can you expand on opening up the oil ways to the rockers. That does sound like a good idea.