Forum

[jefrs]

You've got to ask yourself if a motor with perforated crankcases is worthy of repair. What are the rest of the mechanicals like? Given the history of this one, it looks very much like complete replacement engine and gearbox to me, and usually works out cheaper. Good luck

[Adrian]

What a can of worms this opens up!



Jefrs, I've pointed Lennie in the direction of a new bottom end, though we don't know how well any of the top-end survived! No mention of gearbox troubles, so I expect that's still fine. However, with the engine out of the frame (a good opportunity for a cosmetic repair of the ravages of winter commuting) a 5 speed right-foot shift gearbox would be a nice upgrade!



Scalyback, yes Tornado could go bang, it's a 500 Indian Bullet. Sorry. If that bothers you, make hay while the sun shines. Treat yourself to a spare set of 500 crankcases from our hosts or from Henry Price and stash away until needed. You could also get a complete replacement bottom end put together with one of our host's super-duper crankshaft assemblies and good quality main bearings, and stow that somewhere safe until OEM con-rod doomsday. You could even treat Tornado to a pre-emptive rebuild before it ever goes bang and then you won't need another set of crankcases! If it ain't broke don't fix it is one thing, but if you know impending doom lurks within, you might wish to prepare counter-measures now.



For those suggesting a replacement bike, if you're talking about another Indian (or even Redditch) 500 Bullet, you could be faced with a repeat performance unless you KNEW the P.O. had gone through the engine and sorted every one of all the weak spots listed previously. If I were buying one and planned to keep it, even a good runner, I would have the engine properly rebuilt (as above) as a precaution, especially if I were having the performance bits fitted.



A.

[pphilpot]

Hi guys – you keep specifically mentioning the 500 Bullet, but is this also as much of a threat to a 1991/92 350 Bullet?

Thanks

Paul

[Bullet Whisperer]

Hi Paul, the 350 is a lot less stressed than the 500. BRITISH 500 Bullets can break their conrods around 6000 rpm, probably a good bit less for Indian ones, but for a 350 to feel the stress of a 500 doing 6000 rpm, it would need to be doing 8700 rpm, so don't lose too much sleep over it! Regards, Paul.

[Beezabryan]

Why replace the gearbox?
In 1997 I bought for very little money a 1992 500 Bullet with a similarly trashed engine. A replacement lump was fitted to the existing gear box. apart from replacing a kickstart pawl & return spring in 1998 and a gearshift spring in 2009 the gearbox has been untouched ever since.

[pphilpot]

Thanks Paul.

[Adrian]

The 500's con-rod has to cope with a heavier piston, so more stresses and strains, even when the thing has been properly machined. I have heard of a 350 rod letting go, but it seems to be a lot less common. Unless your 350 is very high mileage or has been seriously thrashed I would be more confident with that than I would be with a 500 which still had its alloy con-rod. If your engine is apart for any reason you could always get the con-rod polished.



There is a school of thought that says that as the Bullet was designed to be a 350 it should have been left as a 350 and never taken out to 500!



A.

[Adrian]

You beat me to it, gents! Must type more quickly.

[Chris Tindal]

I had a Redditch 350 throw a rod at 50mph, very scary.

[Lennie]

I am amazed (and very impressed) not only with the really helpful responses, but that you all took the time to read my Bullet diatribe.



I am now in touch with Paul from Performance Classics, and hopefully will be able to come to agreement regarding a replacement bottom end. There was other damage to the piston crown, which has a large dent in the centre, it looks like the piston hit an open valve during the failure, I cant see any damage to the head, but must assume that there could be valve damage. the Aluminium Barrel has survived, apparently unscathed and still has honing marks, but nothing else having covered 15k miles from new.



I'm still exploring options.... trouble is, its such a great bike to ride. I've had all sorts of bikes over the last 35 years and for some reason which I fail to understand, this is up there with the best of them.



Thanks again