Tech questions answered for old Bullet models.

Ace

Finally made it
Location
E TN, USA
Have a lot of experience with old model Bullets, particularly engine stuff.

Happy to try to help answer member tech questions.

Ace
 

AH3000

Getting there...
Location
Decatur, AL
Ace

I have a 2003 RE Classic ES. Bike had been sitting but a friend of mine got it, got someone to get it running, & gave it to me as he knew I was crazy about old British Cars and Bikes. Someone in the past moved the electric starter button from the handlebar down to what appears a push button/started relay mounted on the front of the electrical/toolbox side compartment. I suspect they did this rather than finding another relay for the bike. I'd like to convert it back to the handlebar. I have gotten a new relay and one from a 2010 Classic. I need some thoughts on how to hook one of them up. Some pictures of the inside of a electric/toolbox side compartment and an idea of what wire runs where out of the box would be helpful. I am also not clear on where the negative cable (lt or medium brown ?) goes. It look like it goes out of the compartment & attaches to 2 small black wires with the ring terminals on the ends. Thx AH3000
 

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Ace

Finally made it
Location
E TN, USA
Hi,
Well, it looks to me as if they have installed a momentary pushbutton switch in the power line to the starter. I don't see any relay there. Probably, that existing switch arrangement would suffice for starting.

However, if you want to use a relay, you can put one in. The typical wiring would be to wire the low current handlebar switch to the coil terminals of the relay(observing polarity), and wire the thick high current starter power wires(inline) to the relay activated switch terminals.

I am assuming that you have not been informed about the problems of the ES system in those pre-unit Bullets? Most owners remove it entirely.
 

AH3000

Getting there...
Location
Decatur, AL
Thanks Ace for responding.
I have only read some of the online info about the sprag starters. I read where Hitchcock's in England offers a blank or filler peice to go in place of the starter. This one seems to work well. It does not engage every time and sometimes, when it does, does not seem fully. But with 2 or 3 tries, it cranks it. Do you know which wires in the box might be the low current handlebar switch? Also, does it seem correct for the brown or negative to then connect to 2 smaller black wires?
 

Ace

Finally made it
Location
E TN, USA
Thanks Ace for responding.
I have only read some of the online info about the sprag starters. I read where Hitchcock's in England offers a blank or filler peice to go in place of the starter. This one seems to work well. It does not engage every time and sometimes, when it does, does not seem fully. But with 2 or 3 tries, it cranks it. Do you know which wires in the box might be the low current handlebar switch? Also, does it seem correct for the brown or negative to then connect to 2 smaller black wires?
I don't have a wiring diagram for your model. You might be able to find one online.
The black wires with the ring terminals are ground wires. The battery is supposed to be mounted there.

You can try to use the ES if it works. Feel free to do that. It will eventually break. They all do. That is why there are kits to remove it.
My advice is to get accustomed to using the kickstarter. That is how these bikes were intended to be started. The ES was put on there for marketing purposes, it always breaks, is expensive to fix, and then it will break again. It was a mistake, and they admit they failed with the ES in these models. It was mostly responsible for the reputation of poor reliability tha Bullets got. There is no proper fix for it.
 

AH3000

Getting there...
Location
Decatur, AL
I'll have to start practicing using the kick starter. I had not been on a bike in about 45 yrs plus so kick starting is not as easy as it used to be. Neither are a lot of other things! 😄
This thing had sat out under a carport so it has some rust on various parts. Any recommendations for parts?
 

Ace

Finally made it
Location
E TN, USA
I'll have to start practicing using the kick starter. I had not been on a bike in about 45 yrs plus so kick starting is not as easy as it used to be. Neither are a lot of other things! 😄
This thing had sat out under a carport so it has some rust on various parts. Any recommendations for parts?
Hitchcock's and ebay are the usual places.
Hitchcock's is reliable and good quality, shipping is costly.
Ebay is a crap-shoot, especially vendors from India. You take your chances and maybe you get a good deal, but maybe you get junk.
 

TN_twowheeladdict

Well travelled
Location
Tennessee
I'll have to start practicing using the kick starter. I had not been on a bike in about 45 yrs plus so kick starting is not as easy as it used to be. Neither are a lot of other things! 😄
This thing had sat out under a carport so it has some rust on various parts. Any recommendations for parts?
Just wanted to make sure you are aware that Allsports in Decatur is a Royal Enfield dealer.
 

AH3000

Getting there...
Location
Decatur, AL
Thank you. I need to ride out there and pay them a visit. Be interesting to see if they have parts for the older bikes. I have been trying to figure out where to get some connectors at so I can try to install my starter relay. The electrical connectors do not look like any I have seen.
 

Eatmore Mudd

Moderator
Staff member
Thank you. I need to ride out there and pay them a visit. Be interesting to see if they have parts for the older bikes. I have been trying to figure out where to get some connectors at so I can try to install my starter relay. The electrical connectors do not look like any I have seen.
Eastern Beaver sources every moto connector you could ever want direct from the manufacturers who supply the bike makers.

Check your message inbox.
 

AH3000

Getting there...
Location
Decatur, AL
New question - What size are the crush washers on the oil drain plugs? Mine are mashed flat so hard they are wicking oil. Tried a pack of 3 assorted sizes from Auto Zone none fit. Two were too small & 1 too big. What re folks using? Thx
 
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