My Royal Enfield Cafe Racer project.

Gordon

Been Around the Block
Hi All,

I've been a member of this forum since a few months and I have to say it has one of the best cafe racer forums I've come across. There's lots of information on this website which has helped me in redoing my bike too into a Cafe Racer.

The bike I currently own is a 2005 Royal Enfield Bullet. Although it cannot do the ton, I have always wanted to have a Cafe Racer look for this bike. Here in India, Royal Enfield manufacturers the Bullet with 2 engine options i.e. 350cc (18bhp) and 500cc(22bhp) which is very less compared to any Cafe Racer. Although distributors / importers across the world offer various accessories, the Indian Company only has Saddle bags and Windshields to offer. The other bikes available here are the Yamaha RD350 and other old British bikes (BSA, Norton etc), but spares are very difficult to source and very expensive. Hence the closest I could come to a British bike was the Royal Enfield which is still being manufactured.

Here are some pics of my bike which is almost complete. The only thing thats left are the front mudguard and a different brand of tyres. All your comments and suggestions are welcome.

The bike when it was first brought :


We started with the "Cafe Racer" project in Jan 07. We started off by getting a new mudguard and shortening it.


Once the mudguard was shortened and fittedm, we realised that it was too high. There was a lot of gap between the tyres and the mudguard. So the frame holding the mudguard had to be cut too. And it wasnt an easy job. At first, everyone thought that it would be an easy job to just cut the frame and lower the mudguard. But it proved to be a bit more complicated To do this first the mudguard was removed and the frame was moved further at the right place to lower the mudguard. However due to another bracket under the seat, it was not possible to just cut the frame. So there were 2 extra holes drilled into the bracket and mudguard and after a lot of hammering the mudguard was finally lowered at both ends. The only problem is that now the frame and the mudguard are not aligned in the same shape.

The bike with the lowered mudguard : The bike looks out of shape now since the seat too is now facing upwards and theres a huge gap between the seat and the tank.


Height before after lowering the mudguard :


Height after lowering the mudguard


Half inch of the frame cut and welded back :


Extra hole drilled into the bracket and mudguard : The lower hole is where the bracket was originally attached.


The frame not aligned with the mudguard :


Royal Enfield is well-known for bad quality paint jobs. Within a year, the paint started peeling off from the engine.


The guard and the exhaust have been removed inorder to get the ebgine out.


The tank is removed too.


Cables being disconnected.


The final moment.


There it sits proudly along with the chain, footrests and other nuts and bolts.


The tank and the Goldstar silencer stored safely.


The engine has been fitted back. The clutch casing is still unfinished. It would be painted matt black. Fitting / Removal of the engine from a bike is really a painful thing to watch. The complete bike is opened up and all your parts are scattered here and there. There's a huge risk of mechanics dropping nuts, bolts, spanners on these parts especially the tank when its just lying around. Looking at the mechanic hammering a nut with a huge hammer could literally really give you heart attacks. There was lot of nut-banging done, however we ensured that no parts were damaged and scratched.


The BSA light which would be fitted onto the bike.


The BSA Goldstar seat fabricated for the Enfield. It turned out that the fabricated base was longer than the original seat and would need some cutting and shaping. The shape would be very much similar to the Goldstar seat.
The fabricated base as compared to the original seat.


Taking measurements to get the base-metal into shape.


The Machismo with a proper "impractical" Cafe-Racer seat.


Pics of the brackets made for the BSA light and registration plate.


The sharp edged mudguard:


Marking and cutting for folding the edge:


Cutting a part of the curved edge so that it can be bent easily.


Beating the edge. Halfway through:


Drilling common holes for the brackets:


Fitting the taillamp and plate:


Lying around before painting:


The handlebar has been fitted. It looks good but has a few problems.

  • On full turn, the decompression switch touches the tank.
  • The reach is quite far and u-turn's are somewhat difficult. A lot of load comes on the wrist currently and its very uncomfortable in traffic. Navigation through traffic is also not very easy. The handlebar needs to be pulled back an inch or two and raised.


The exhaust was cut and bent upwards.


Pics of the tail-light and the handlebar.


The footpegs had to be raised a bit higher to accomodate the silencer. See the difference in the height between the original silencer and the raised one.
silencertu2.jpg
 

CanadaDan

1977 BMW R75/7 'Mojo'
Great project!

It's funny... over here the Enfield has almost a cult following... it's all about parts isn't it!

Just do what feels and looks right and it'll be a cool bike!
 

locOleoN

Is that the best you got? OK.. now my TURN...
Hey Gordon,

Welcome to the site!!.. your project looks great!!.
Ur in India??!!.. Do you see a lot of Cafe Racers on the street?... If not, UR certainly be the first!!..
HOw about Heidi desigining a "Do The Ton Cafe Racer - India" patch!! ;D
 

Gordon

Been Around the Block
CanadaDan ]over here the Enfield has almost a cult following[/quote] [quote author=locOleoN said:
Hey Gordon,

Welcome to the site!!.. your project looks great!!.
Ur in India??!!.. Do you see a lot of Cafe Racers on the street?... If not, UR certainly be the first!!..
HOw about Heidi desigining a "Do The Ton Cafe Racer - India" patch!! ;D

Yes, we are located in Bombay, India. There are rarely some cafe racers here. Most do not know about cafe racers. They're more into Choppers. Choppers are generally built on the Enfields. Royal Enfield is the only British (now Indian) bike sold in India officially. There is a huge cult following for Royal Enfields in India.

[quote author=CanadaDan]Just do what feels and looks right and it'll be a cool bike![/quote]

Yes. I have always been adamant that the quality of the parts fabricated or added onto the bike should be high.
 

Gordon

Been Around the Block
Guys, I need some help. If you could please guide me:

  • Speedometer Dial
    Its currently white in color.
    Speedometer-Royal-Enfield-Bullet-N-M.jpg

    How to change the face of the speedometer dial?
    Can I make a custom one, with my own print?
    What am I supposed to use?

  • Tax-Disc Holder
    I am planning to make my own custom tax-disc holder. It will be an illuminated (backlight) type. This is how I plan to make the tax-disc holder - buy two outer-coverings (the chrome ring and the plastic) of the speedometer, fabricate a small bracket to install it on the bike, I have already designed a name and logo for the motorcycle which I plan to put in the tax-disc holder. The questions are:
    What type of paper/plastic or whatever should I use to print on?
    What bulb do I use that would provide enough light AND be small enough?

Anything else I should look into / change / or add?

Attached a pic of the bike. Will post detailed pics of the whole bike when EVERYTHING is ready.
The handlebar is supposed to be lowered a few mm's more.

caferacerpq0.jpg
 

Fossil

Active Member
Way back there were "Big Head Bullets" with extra finning, downdraft intake, larger valves etc. built to compete against Goldstars on American flattracks. Tuning equipment is available more power out of the Bullet. There were Bullet racers featured in Classic Racer now and then.
 

Gordon

Been Around the Block
Fossil said:
Way back there were "Big Head Bullets" with extra finning, downdraft intake, larger valves etc. built to compete against Goldstars on American flattracks. Tuning equipment is available more power out of the Bullet. There were Bullet racers featured in Classic Racer now and then.

I guess ur refering to the Royal Enfield Interceptor. It was a 750cc parallel twin producing around 55 bhp. Then there was also the Royal Enfield Constellation and the Meteor.
Nowadays Bullets's are made keeping in mind the rideability and fuel efficiency in mind. Hence 350 cc with a measly 18bhp.
 

Gordon

Been Around the Block
Fossil said:
Nope, I'm referring to the 500cc single cylinder Bullet.

Yes. I have mentioned that in the opening post. Royal Enfield provides two variants in India. A 350cc and a 500cc. Both are single cylinders. The 500cc is just 4 bhp more than the 350cc (18bhp).

Don't know about the "Big Head Bullets" you're talking about. Have any more info on them?

Edit: Just checked on Google. It was in 1959 itself. The Indian Bullet has almost the same 500cc engine the BigHead Bullet had then, but its quite reliable these days. Don't know about the power specifications though. Recently, Royal Enfield introduced 500cc AVL engines.
 

locOleoN

Is that the best you got? OK.. now my TURN...
DOnt mind me and my lack of comments on your thread... I'm just jealous and lameting on how everyone else has a nice bike.
 

Gordon

Been Around the Block
The print for the tax disc holder is ready. Have to fabricate the tax disc holder now. Other small bits are also being done. Will post as and when its ready.

Anyone with any tips about the Speedometer Face?!
 

Gordon

Been Around the Block
Checked out for mirrors for the bike. Tried on all sort of mirrors before finally settling for the Eliminator one. The other mirrors available in the market are not of good quality. I guess only the Eliminator and Enticer come with chrome mirrors. The Enticer mirror does not suit the bike as much as the Eliminator one. Have installed only a single mirror.

A bar-end mirror was initially planned but it would stick out of the handlebar so .....
mirrorslm4.jpg
 

Gordon

Been Around the Block
Thank you for the appreiciation.

Rearsets:
Could anyone give me some information about rearsets and linkages?! I was just pondering on the possibilities and have these ideas:

- Rotate the rear footpeg towards the front. That darkbrown part of the engine is yet to be painted. Black.
rearsetssg3.jpg


- Create linkages (This is exactly what I'd like to know. Is it possible to get some stuff and make it on my own?)
 

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