This is not a complete or flawless instructional video - although you may get all the info you need from it if you have some experience with engine repair.
It was done in a parking lot of our hotel because as long time friends of this channel may recall - Royal Enfield threatened my dealer with revoking his license if he allowed videos to be made in his workshop (actually they threatened him in case the existing vids where not removed but never followed up on that threat).
So I grabbed my favorite mechanic on his day off and we got the ball rolling. Yes, the bike is super dirty, the washing facility in the shop does not work since weeks (this is India) and I had no idea of the extend of dust under the various covers. Also: we had used the head gasket from the 410cc Big Bore and when fire up the first time the piston made an audible sound so we had to re-do the entire thing after we widened the gasket to the size of the 500cc piston.
After installation of the piston we also did the Powertronic V4 but that process is sufficiently explained in their manuals and needs no extra video IMO. However, the 500cc will NOT run properly with cutouts, stalling at low rpm and less power UNTIL the mapping is done right. After a few trial runs I used a slightly modified map from my Euro5 Himalayan V4 Powertronic that worked quite nice. There is still knocking when accelerating sharply so timing needs adjustment but I'd say its 80-90% correct - not bad for not having a dyno to check.
7 янв 2024
