Congratulations! You have chosen to begin a journey astride a machine that has taken ten years of heart, mind and body to metamorphose into a timeless, organic motorcycling experience. I am delighted to now share this experience with you, whether you've just come across it or have supported it from the beginning.
Whether you decide to build your own bike with this engine or you choose to have your own Musket built by me, you will have a lot of fun riding, tinkering, making it your own, feeling connected to a community that values the visceral satisfaction of form and function being united after serious, committed effort.
Please read through the TECH. page to get familiar with the design and its rationale.
Whether you decide to build your own bike with this engine or you choose to have your own Musket built by me, you will have a lot of fun riding, tinkering, making it your own, feeling connected to a community that values the visceral satisfaction of form and function being united after serious, committed effort.
Please read through the TECH. page to get familiar with the design and its rationale.
All custom pieces to modify the frame and complete the build will be available for purchase to all DIY builders.
An overview of the entire process can be seen in the gallery below.
An overview of the entire process can be seen in the gallery below.
How it's done. From Bullet to Musket:
The heart of the project is the Musket crankcase which will come with all internal components installed and timed, ready to accept top ends and transmission. Emerging from painstakingly crafted patterns that took years of development from the first version to the new production design, the castings are made the old-fashioned way with sand molds. As shown in the gallery above, the crankcase castings go through 15 separate machining setups, each of which includes several facing, milling, drilling, reaming and tapping operations. Furthermore, the V twin crank is built by machining the flywheels to re-balance and a custom crankpin is also made to allow two conrods. It all comes together in a motor with a character and personality that looks, feels and sounds true to its vintage roots.
The Musket has been designed for the original iron barreled version of the Royal Enfield Bullet, kick-start version. Electric-start bikes are perfectly viable and will simply need a new kick-start type inner primary cover.
The information on this page is deemed correct to the best of my knowledge but in case of an error or omission, it will be corrected or updated.
The Musket has been designed for the original iron barreled version of the Royal Enfield Bullet, kick-start version. Electric-start bikes are perfectly viable and will simply need a new kick-start type inner primary cover.
The information on this page is deemed correct to the best of my knowledge but in case of an error or omission, it will be corrected or updated.
FAQ. PLEASE READ.
1. Will the engine be available in India?
First and foremost, any sort of custom engine/frame/modification of the sort that this project involves, is *illegal* in India.
Yes, that is the crushing truth. This was originally made for the Indian Bullet fanatic but the law doesn't allow a Bullet owner to swap out his motor with this. This isn't the same as a chopped Bullet. This motor fundamentally and very visibly changes the specs of the bike from single to twin, 350 to 700, 500 to 1000, wheelbase as well.
If you are in India and do want to order the engine, please do your research about getting permission from your RTO to do this major mod, registering, getting insurance, emission check etc. Secondly, factor in the cost of shipping and the hefty import duty ( I've been told that it is around 26-30% for something like this but don't know for sure).
Next, let's say you do install this in your Bullet/custom bike. The chances of this thing getting stopped by police at a random check/pollution test and getting impounded are pretty high. It will be difficult to explain how your engine just happened to sprout a second head and believe me, it won't escape the eyes of the most lethargic cop.
In any case, to do it all properly will need a *trained and approved* workshop/s to provide necessary support. For right now, lets hope that things work out and Indian laws on custom vehicles made in small numbers allow projects like this to be legal.
2. What models of the Royal Enfield Bullet are suitable for this engine?
ANY Bullet with the original, iron barrel engine can be used, depending on engine size desired. 350s will be perfect for a 700, 500s for the 1000. This doesn't mean that a 350 can't get a 1000 engine or a 500 can't be converted to 700 but the bikes will provide the correct donor top end needed.
Electric start bikes will simply need a new kick-start style inner primary cover which will be provided for turnkey builds.
3. Does it matter which gearbox/shifter side my bike has?
No. Both 4spd and 5 spd gearboxes will fit. The old 4 spd Albion style box with neutral finder will require right side shift as the USA export version's left-shift linkage doesn't allow the larger 21t gearbox sprocket to fit.
5 spd boxes can be fitted with stock left shift but require the clutch inner and outer covers with shifter rod holes and seals (getting a bit hard to find). This can be done to std. clutch cases by welding, drilling, boring but will cost extra.
Left shift bikes with brake on right will only have room for a single exhaust pipe on the right, thus needing a 2x1 pipe on right or a 2x2 pipe with front pipe exiting to left of bike, same as in the 998 prototype.
4. How does the Musket engine fit into the frame?
Exactly as the stock single cases. The 4 gearbox stud locations are identical and the case bolts to the gearbox. The rear frame-to-crankcase stud hole is also the same. Front engine plates are custom and available, they bolt to the frame downtube 'tee' same as stock. The top tube is stretched approx. 6" and the tube needed can be provided (it is 1.75" OD 1.5" ID and telescopes onto the bike's own top tube) or the builder can do this him/herself.
5. Is electric start available?
No. In the interest of keeping this as simple, light and true to classic British twins, this motor is kick-start only. Electric start will also add considerably to cost.
6. Will high-performance. Bullet parts drop in?
Yes but keep in mind the effect on transmission, clutch, frame, braking etc. The bike is already getting double capacity and output and in the interests of longevity, some compromises must be made.
1. Will the engine be available in India?
First and foremost, any sort of custom engine/frame/modification of the sort that this project involves, is *illegal* in India.
Yes, that is the crushing truth. This was originally made for the Indian Bullet fanatic but the law doesn't allow a Bullet owner to swap out his motor with this. This isn't the same as a chopped Bullet. This motor fundamentally and very visibly changes the specs of the bike from single to twin, 350 to 700, 500 to 1000, wheelbase as well.
If you are in India and do want to order the engine, please do your research about getting permission from your RTO to do this major mod, registering, getting insurance, emission check etc. Secondly, factor in the cost of shipping and the hefty import duty ( I've been told that it is around 26-30% for something like this but don't know for sure).
Next, let's say you do install this in your Bullet/custom bike. The chances of this thing getting stopped by police at a random check/pollution test and getting impounded are pretty high. It will be difficult to explain how your engine just happened to sprout a second head and believe me, it won't escape the eyes of the most lethargic cop.
In any case, to do it all properly will need a *trained and approved* workshop/s to provide necessary support. For right now, lets hope that things work out and Indian laws on custom vehicles made in small numbers allow projects like this to be legal.
2. What models of the Royal Enfield Bullet are suitable for this engine?
ANY Bullet with the original, iron barrel engine can be used, depending on engine size desired. 350s will be perfect for a 700, 500s for the 1000. This doesn't mean that a 350 can't get a 1000 engine or a 500 can't be converted to 700 but the bikes will provide the correct donor top end needed.
Electric start bikes will simply need a new kick-start style inner primary cover which will be provided for turnkey builds.
3. Does it matter which gearbox/shifter side my bike has?
No. Both 4spd and 5 spd gearboxes will fit. The old 4 spd Albion style box with neutral finder will require right side shift as the USA export version's left-shift linkage doesn't allow the larger 21t gearbox sprocket to fit.
5 spd boxes can be fitted with stock left shift but require the clutch inner and outer covers with shifter rod holes and seals (getting a bit hard to find). This can be done to std. clutch cases by welding, drilling, boring but will cost extra.
Left shift bikes with brake on right will only have room for a single exhaust pipe on the right, thus needing a 2x1 pipe on right or a 2x2 pipe with front pipe exiting to left of bike, same as in the 998 prototype.
4. How does the Musket engine fit into the frame?
Exactly as the stock single cases. The 4 gearbox stud locations are identical and the case bolts to the gearbox. The rear frame-to-crankcase stud hole is also the same. Front engine plates are custom and available, they bolt to the frame downtube 'tee' same as stock. The top tube is stretched approx. 6" and the tube needed can be provided (it is 1.75" OD 1.5" ID and telescopes onto the bike's own top tube) or the builder can do this him/herself.
5. Is electric start available?
No. In the interest of keeping this as simple, light and true to classic British twins, this motor is kick-start only. Electric start will also add considerably to cost.
6. Will high-performance. Bullet parts drop in?
Yes but keep in mind the effect on transmission, clutch, frame, braking etc. The bike is already getting double capacity and output and in the interests of longevity, some compromises must be made.
Prices.
Do it yourself:
1. Complete Musket crankcase, std setup: $6990 + any applicable taxes & shipping
Machined cases, shot-blasted, ceramic high-temp. paint coated, with following installed:
1. Custom v twin crank with custom crankpin, stock conrods, stock big ends, static balanced, trued.
2. Timing pinion, cam spindles, cams. Cam timing done with dial indicator.
3. Tappets and guides.
4. Complete oil pump setup with worm gear, spindle, discs, plungers, springs
5. Oil feed plug.
6. Twin C.B. points setup, custom point shaft, advance unit, ignition timing done.
7. Custom external oil lines from sump to pumps with custom stainless banjo bolts.
8. Oil filter cover: turned, machined 6061T6 alloy
9. Custom Oil sump pickup banjo bolt with mesh screen. Included.
10. Oil filler neck: machined, turned 6061T6 alloy, uses stock oil filler cap with extended dipstick.
11. Custom ignition points cap engraved with logo: machined, turned 6061T6 alloy. Want custom engraving? Inquire in your order form.
12. Oil filter.
Note: Oil outlet on timing cover for feed to heads is threaded to accept stock rocker pipe oil union 140122 or head banjo bolt 144591, 5/16-26tpi BSC threads.
1. Custom v twin crank with custom crankpin, stock conrods, stock big ends, static balanced, trued.
2. Timing pinion, cam spindles, cams. Cam timing done with dial indicator.
3. Tappets and guides.
4. Complete oil pump setup with worm gear, spindle, discs, plungers, springs
5. Oil feed plug.
6. Twin C.B. points setup, custom point shaft, advance unit, ignition timing done.
7. Custom external oil lines from sump to pumps with custom stainless banjo bolts.
8. Oil filter cover: turned, machined 6061T6 alloy
9. Custom Oil sump pickup banjo bolt with mesh screen. Included.
10. Oil filler neck: machined, turned 6061T6 alloy, uses stock oil filler cap with extended dipstick.
11. Custom ignition points cap engraved with logo: machined, turned 6061T6 alloy. Want custom engraving? Inquire in your order form.
12. Oil filter.
Note: Oil outlet on timing cover for feed to heads is threaded to accept stock rocker pipe oil union 140122 or head banjo bolt 144591, 5/16-26tpi BSC threads.
2. Complete Musket crankcase, Carrillo* rods, bronze bush big ends: $7690 + any applicable taxes + shipping
ACE performance has switched to a simpler, more affordable bronze bush big end with forged steel Carrillo rods for a very robust bottom end.
This is the setup recommended by Chumma of ACE to accommodate their performance products on this engine.
Musket V twin builders buying ACE products for their engine will be qualified for a discount from ACE.
*Carrillo is the trademark of CP-Carrillo.
NOTE:
Prices require your 500cc lower end with useable donor parts.
Donor parts will be rebuilt/replaced with new ones if required, after inspection and discussion with customer, at additional cost.
In addition, the complete conversion of your 500 Bullet to a running Musket will also need the following CUSTOM parts and/or mods to stock parts that are needed to complete the project, apart from stock parts such as the extra top-end, carburetor, ignition-electrical etc .
You can choose to make/do these on your own or I can provide the parts and instructions or the service itself, depending on what you need done. Complete parts list with prices coming soon.
1. Pushrods: Shortened stock pushrods. Need to be made to suit each valve seat height as this varies if your seats have been cut. I can make these to correct fit from your measurements on your head.
2. 2 Curved intake manifolds, one for each head.
3. Larger dia. clutch spring plate: Steel, holds 9 springs instead of the stock 6 for 50% increase in pressure.
4. Mounting bracket to hold twin ignition coils.
5. Large capacity oil breather catch-can.
6. Throttle cable 2into1 unit for twin carbs. The "Y" has unequal lengths due to the location of the front and rear carbs.
7. Frame top-tube stretch tube and fasteners.
8. Custom front engine mounting plates.
9. Front head-to-frame brace.
10. Gas tank repositioned- moved backwards to compensate for frame stretch and re-centralize above "V" top ends.
11. Old gas tank mount hole in headstock and gap between gusset and tank concealed with sheet metal cover.
12. Seat moved forward to compensate for frame stretch. Note: The standard 'dual seat' is not recommended, solo seats will be vastly preferable in terms of aesthetics and fitment flexibility.
13. Cylinder heads are machined to fix studs on either side of exhaust port for secure pipe attachment to heads.
14. Exhaust pipe cooling rings/collars are drilled for studs described above.
15. Stainless steel exhaust pipes fabricated.
16. Fuel line tee to branch fuel hose to feed 2 carbs.
17. Breather hoses from cases to catch-can, catch-can to suitable outlet location.
This is the setup recommended by Chumma of ACE to accommodate their performance products on this engine.
Musket V twin builders buying ACE products for their engine will be qualified for a discount from ACE.
*Carrillo is the trademark of CP-Carrillo.
NOTE:
Prices require your 500cc lower end with useable donor parts.
Donor parts will be rebuilt/replaced with new ones if required, after inspection and discussion with customer, at additional cost.
In addition, the complete conversion of your 500 Bullet to a running Musket will also need the following CUSTOM parts and/or mods to stock parts that are needed to complete the project, apart from stock parts such as the extra top-end, carburetor, ignition-electrical etc .
You can choose to make/do these on your own or I can provide the parts and instructions or the service itself, depending on what you need done. Complete parts list with prices coming soon.
1. Pushrods: Shortened stock pushrods. Need to be made to suit each valve seat height as this varies if your seats have been cut. I can make these to correct fit from your measurements on your head.
2. 2 Curved intake manifolds, one for each head.
3. Larger dia. clutch spring plate: Steel, holds 9 springs instead of the stock 6 for 50% increase in pressure.
4. Mounting bracket to hold twin ignition coils.
5. Large capacity oil breather catch-can.
6. Throttle cable 2into1 unit for twin carbs. The "Y" has unequal lengths due to the location of the front and rear carbs.
7. Frame top-tube stretch tube and fasteners.
8. Custom front engine mounting plates.
9. Front head-to-frame brace.
10. Gas tank repositioned- moved backwards to compensate for frame stretch and re-centralize above "V" top ends.
11. Old gas tank mount hole in headstock and gap between gusset and tank concealed with sheet metal cover.
12. Seat moved forward to compensate for frame stretch. Note: The standard 'dual seat' is not recommended, solo seats will be vastly preferable in terms of aesthetics and fitment flexibility.
13. Cylinder heads are machined to fix studs on either side of exhaust port for secure pipe attachment to heads.
14. Exhaust pipe cooling rings/collars are drilled for studs described above.
15. Stainless steel exhaust pipes fabricated.
16. Fuel line tee to branch fuel hose to feed 2 carbs.
17. Breather hoses from cases to catch-can, catch-can to suitable outlet location.
Let me do it for you:
1. Complete build on your 500 Bullet, ready to ride, stock setup: $11,990
Note: For reasons of sanity, only engine build and installation work is undertaken. Paint & bodywork is not offered.
After completion, tuning, jetting and adjustments are made, oil flow checked and the bike is ridden and observed for at least 50 miles. Re-jetting for free-breathing pod filters and free flow mufflers typically involves new idle jets, needle jets and main jets and is elevation sensitive. You may have to adjust further after more miles.
1. Requires your Bullet 500 in good running condition. Engine and clutch oil must be drained prior to shipping.
Electric start bikes will need a new kick-start style inner primary cover and engine sprocket, in stock.
2. Price assumes customer bike has good head, bore, piston and compression, original top-end will be re-used/refreshed. Second complete top end, brand new, will be provided and is included. If necessary or if customer prefers, 2 new barrels and 2 new std. bore stock pistons can be fitted, at cost.
3. Price assumes stock cast iron barrel and stock piston. Alloy barrels and/or aftermarket pistons can be fitted at cost.
4. New stock Mikcarb included. New jets included for both carbs.
5. If existing cylinder head requires work such as new valves/seat grinding, this will be quoted upon dismantling and checking.
6. Brand new second head with all necessary parts is included
Brand new second head with all necessary parts is included7. If existing clutch and/or transmission need repair, this will be extra.
*Plus any applicable taxes and shipping.
*Includes 2x2 stainless exhaust pipes on right only, for a bike which already has right-side-shift. Does not include mufflers. Mufflers will be selected by client and pipes will be fabricated to suit. Head-pipe style will be similar to the 1120.
2x2 pipe-on-each side (as in 998 prototype) is more complex to fabricate and will be $200 extra.
Pipe on right with custom-made 2x1 "Y" pipe will be $250 extra.
Pipes can be made up-swept as in 1120 or horizontal.
NOTE: All left-shift bikes can accommodate only single pipe on right due to brake lever. This requires 2x2 pipe setup with 1 pipe on each side OR custom 2x1 "Y" pipe.
If right side shift conversion is desired, this can be done at extra cost, for both 4spd or 5 spd gearboxes and is approx. $400 for parts and labor.
Electric start bikes will need a new kick-start style inner primary cover and engine sprocket, in stock.
2. Price assumes customer bike has good head, bore, piston and compression, original top-end will be re-used/refreshed. Second complete top end, brand new, will be provided and is included. If necessary or if customer prefers, 2 new barrels and 2 new std. bore stock pistons can be fitted, at cost.
3. Price assumes stock cast iron barrel and stock piston. Alloy barrels and/or aftermarket pistons can be fitted at cost.
4. New stock Mikcarb included. New jets included for both carbs.
5. If existing cylinder head requires work such as new valves/seat grinding, this will be quoted upon dismantling and checking.
6. Brand new second head with all necessary parts is included
Brand new second head with all necessary parts is included7. If existing clutch and/or transmission need repair, this will be extra.
*Plus any applicable taxes and shipping.
*Includes 2x2 stainless exhaust pipes on right only, for a bike which already has right-side-shift. Does not include mufflers. Mufflers will be selected by client and pipes will be fabricated to suit. Head-pipe style will be similar to the 1120.
2x2 pipe-on-each side (as in 998 prototype) is more complex to fabricate and will be $200 extra.
Pipe on right with custom-made 2x1 "Y" pipe will be $250 extra.
Pipes can be made up-swept as in 1120 or horizontal.
NOTE: All left-shift bikes can accommodate only single pipe on right due to brake lever. This requires 2x2 pipe setup with 1 pipe on each side OR custom 2x1 "Y" pipe.
If right side shift conversion is desired, this can be done at extra cost, for both 4spd or 5 spd gearboxes and is approx. $400 for parts and labor.
Polishing of camcover: $350
Polishing of castings to a shiny, reflective finish is very laborious and time-consuming but does look wonderful. Sanding is begun at 100 grit and is taken all the way upto 2000 grit before polishing compounds are used to bring out shiny reflections. The most prominently visible part of the engine is the cam-cover. This would need to be done before assembly. It balances nicely with the clutch cover on the opposite side of the engine.
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Please double-check that your email address is accurate to ensure I can reach you. In the Details box on left, please include the following information: 1. Your Bullet's year, miles, gearbox, right or left shift, kick or electric start. 2. Complete build or crankcase kit only. 3. Interested in stock bottom end or Carrillo-roller. 4. Any existing modifications to bike. 5. Condition of top end if known: compression, valves, guides, rockers. 6. Exhaust pipe style desired. 7. Any other queries or information about your project. |