Royal Enfield Continental GT Big Bore 865, Cam, Clutch, Exhaust, Power Commander, FULL INSTALL
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- Опубликовано: 20 июн 2024
- The full video on installing the S&S Big Bore 865 kit, Performance Cam, Recluse Clutch upgrade, Power Commander 6, Diablo Exhaust, and Air Injection Blanking kit on a Royal Enfield Continental GT 650/Interceptor 650. Leave a like if you like the content! Leave a comment if you have some advice, or a question. While I am not a mechanic, I hope this helps someone in the future to install the same products! Below are links to kits, parts, essential tools, and products:
I do get a commission on the Amazon and Ebay links. It would be kind of dumb of me not to use affiliate links where possible, but do not feel obligated use them.
Big Bore Kit accessories.hitchcocksmotorcy...
8 Cylinder Head Bolts, part number 575620 accessories.hitchcocksmotorcy...
Stage 2 Cam accessories.hitchcocksmotorcy...
Power Commander 6 Pre-mapped accessories.hitchcocksmotorcy...
Ferodo Front Brake Pads accessories.hitchcocksmotorcy...
Ferodo Rear Brake Pads accessories.hitchcocksmotorcy...
Exhaust Sensor Blanks accessories.hitchcocksmotorcy...
Air Injection Delete Kit accessories.hitchcocksmotorcy...
Clutch Upgrade Kit accessories.hitchcocksmotorcy...
Perrelli Sport Demon Front Tire 110/90 r18 amzn.to/3QSYFbG
Perrelli Sport Demon Rear 140/70 r18 amzn.to/3LDyXap
Royal Enfield Special Tool 30300 TDC Crank locking tool accessories.hitchcocksmotorcy...
Royal Enfield Cam - TDC Aligning Plate PN ST30260/A www.bike-parts-royalenfield.c...
Royal Enfield Crank Gears Locking Tool Part Number - ST-27533-2 www.bike-parts-royalenfield.c...
Angle Torque Meter amzn.to/3QPjQvf
Valve Spring Compressor amzn.to/3diZ75z
Circlip Plier Set amzn.to/3LnR3g9
Piston Ring Compressor Kit amzn.to/3UmoJyQ
Piston Ring Expander (Didn't need these for this kit) amzn.to/3eSK4Q9
Digital Torque Wrench amzn.to/3RVKHal
TOOLGUARDS 26 Pieces INCH/MM Ratcheting Wrench Set amzn.to/3QXXDv4
PB BLASTER PENETRATING CATALYST amzn.to/3UjEZkg
Permatex Copper Gasket Sealer Spray amzn.to/3DA9GMe
Castrol 10w-50 Motor Oil amzn.to/3SimF9r
Mahle Oil Filter amzn.to/3qNX9wR
Lucas Oil Assembly Lube amzn.to/3Bq9IDz
Redline Axle Grease amzn.to/3qSoVZ9
Maxima 15w-50 Motorcycle Break In Oil amzn.to/3fi7PRR
An unofficial Royal Enfield 650 maintenance manual: drive.google.com/file/d/1EPfo...
Recluse Clutch Install document: rekluse.com/wp-content/upload... Take note that all plates are slotted into the same slot on the basket. Do not use the small outer slots.
00:00 The Plan
02:18 Unboxing
09:46 New Tires and Brakes
12:38 Clutch Kit Overview
17:34 Air Injection Delete Kit Install
23:47 Clutch Install. ALL PLATES GO IN MAIN SLOT
40:21 Tank Removal
43:03 Blanking O2 Sensors
45:24 Exhaust Removal
47:28 Spark Plugs, Rocker Cover Removal
48:50 Removing Rocker Carriers
50:29 Remove Timing Chain Tensioner
52:35 Remove Cam Shaft
55:15 Remove Cylinder Head
1:01:06 Remove Cylinder Barrel
1:03:56 Big Bore Kit Overview
1:05:56 Add Valve Shims
1:24:11 Replace Pistons and Cylinder Barrel
1:30:55 Power Commander Install
1:35:00 Install Cylinder Head
1:45:07 Cam Timing Overview
1:46:54 Diablo Exhaust Install
1:49:20 Royal Enfield Special Tools Overview
1:51:00 Cam Timing Final Plan
1:52:51 Using The TDC Locking Tool
1:54:11 Installing The New Cam Shaft
2:00:06 Install Timing Chain Tensioner
2:03:10 Install Rocker Carriers and Cam Alignment Fix
2:06:21 Tappets Clearance Adjustment
2:09:40 Replace Rocker Cover and Horns
2:11:07 Replace Clutch Cover
2:14:25 Securing The Gas Tank Area
2:15:49 Break In Oil and Breaking In Plan
2:20:29 Plugs
2:21:49 First Start
2:25:07 Oil Leak Discovered and Fixed
2:29:43 Success Declared and Analysis 
Авто/Мото
You are a patient and skilled mechanic to add the task of filming & editing to an already labor intensive project; my back got sore just watching it. Now I feel it's doable after seeing it successfully completed, even for the zip tie mechanic that I am. Thanks so much for all the hard work of putting this video together. 👍
Thank-you very much! It was my first time for almost everything in this video. I just followed the instructions that came with the products as closely as possible, used the RE assembly manual, and tried to plan it out. There were surprises along the way. Hopefully this is a good resource.
Its often common sense, dont under estimate yourself.
Man, this video is amazing! I always search for twin 650 content and it's dificult to find. Thank u for the contribution.
Thanks!
This video deserves 100 likes for going above and beyond! What an epic project and mucho respect for taking it on. Also great that on reflection you would have taken it to a shop! I was thinking that the whole way through your video! 😂 Hope the bike lives up to your expectations, you did an excellent job!
Great build video, can't wait to see her on the road.
I highly appreciate this video and the description of the parts needed from Hitchcocks Motorcycles.
You are welcome!
Thank you for documenting all this. Very useful.
Wow. I enjoyed your work's outcome. Good job mate
Excellent presentation. I learned a lot. Thanks
Congratulations mate. You should be rightly proud of what you’ve done 👍
Damn that’s a beautiful bike
Thanks! It is nice to get the looks at stop lights. I'm not going to lie.
@@OakInch Yeah man I hear ya… I ride a Triumph Thruxton 900 and it turns heads as well. These café racers get a lot of love! I want a Royal Enfield next 👍
Thank you so much for making this video. Totally agree with you the performance needs to match the looks cuz everyone wants to race at a stoplight - at least that is my experience.
I have an S&S Cam, DNA filter, full headers and S&S mufflers on my 2020 interceptor. The downloaded map from HC did not work well for me so I took it to get it tuned and it made a HUGE difference in torque after the tune. Unfortunately, after all of this, I still need more power, especially passing power. I’ve done a lot to my bike as well and I want to enjoy riding it more - an 865 kit is something I’ve been looking at very closely.
I’m subscribed and I’m really looking forward to hearing your impressions on the bike - sound as well as performance. Hoping we can see a RAW video of you rippin’ on the bike soon. Take care!
Superb one, thanks for this. It communicated clearly each step, the tools, the pain, your patience and the satisfaction & joy at last… ❤
Expecting a complete review of this modified beast in comparison of stock GT, which is equally needed fo those thinking of a big bore, pls do…!
Great and detailed project, you should really be proud
Thanks!
This is the best thing I’ve seen on RUclips for continentals. You did such amazing work and I’m super grateful thank you.
I’ve been debating doing the same mods to my GT. Im just so grateful to see people like you making such great content that helps me so much, can’t thank you enough. If I can swing the money I’ll be doing the same. Cheers!
Thanks! I appreciate it. I hope it helps people. I really made these videos because I couldn't find any good info. I thought would pass on some info for the next guy.
Wow!! Really nicely done!!
Your bike looks very nice and I am sure you are enjoying the motorcycle!!
Thanks! Hopefully it will warm up this weekend and I can get the 500 mile review of the upgrade completed.
Wow what a great video.
Very detailed.
Thank-you! I hope it is useful.
Thank you, thank you, thank you! For saying how much you paid for everything!!!.... Your bike looks, and sounds absolutely amazing. I can't wait for upgrade hp numbers. Thanks
Hey, I'm waiting so much for your next video. Please do drop the details like 0-60, total on the wheel power gain.
This is not only the best video on the subject of big-bore kit installation, it is the ONLY video; at least so far. I bought two of the S&S 750cc bore kits in the Spring of 2022 and have had 2 different machine shops "help" with the work (I am building 2, one all stock and another with the S&S cam and the clutch upgrade). The first one cost $1,500 above the cost of my INT650 which was $5,949 so right at $7,500. This includes 8 new head bolts, base gasket that doesn't come in the S&S kit and the Motul 10w40 mineral oil. I have extensive air-cooled VW/Porsche specialty tools and 50+ years of experience so didn't have to purchase anything additional.
You are using the same oil temp gauge that I use on my INT650 and 3 Triumphs; highly recommended.
Looking forward to your riding videos on your 863cc Enfield, only the Triumph can claim a full 865cc!
Again, thanks for the very detailed and informative video; hats off to your efforts on this "built, not bought" motorcycle. Fred in Virginia.
Edit: 6•11•2024 one year and 14,000 miles on the big-bore kit and S&S cam and could not be happier with the results. I am just now installing the Rekluse clutch coming up on an oil change at 42,000 total miles. It is wearing out rear tires at an increased rate with the added power and compression braking.
Thanks Fred! I am hoping that I left some good info for the next guy that tries this on his own. Good info was hard to find before I started. I guess I'll have to start calling it the 863 from now on--Now that I know that number is reserved and I can't round up!
@@OakInch my "750" is 742.54 cc and the 90mm pistons using the R E. 67.8mm stroke is 862.65 cc's; they are 743cc and 863cc respectively.
Thankyou for your hardwork and teaching us. 🙏
No problem. I hope it helps someone else if they decide to do it.
@@OakInch 🙏😇
Great video.
Great job, great video.
I appreciate it. Thanks!
Great work done..
Thanks! I hope the info is useful.
thanks a lot, great video for others to follow
Thanks! I want to leave some info for the next guy.
You sir have the best looking continental gt out there. I do prefer the look of the wrapped pipes (and the black), I would cut out the cat and weld in a new length of pipe. I'm looking forward to seeing a ride/grin video!
I do miss the wrapped pipes. I may wrap these in the future, and paint, or get a black set of slip ons. It does add a more custom look. I don't hate the shiney pipes, so I am not super motivated to make the change.
Great vid!
Thank you! I hope it is useful to people doing these projects, or at least a good ASMR video for people who can't sleep. Haha.
wow. your bike must be an insane fun ride,I only have DNA filter&open exuast upgrade on my Conti&it's very different to stock,yours would be a monster of fun...amazing work mate👍instant subscription to your channel worthy...personally the big bore isn't for me,but I still like seeing others enjoying there hard work,&the fact your diu ,best ever ..
Thanks! I appreciate it.
Thanks for taking ‘one for the team’ of RE650 twin enthusiasts with the build of your bike. This is a great resource for anyone contemplating similar mods and a great step by step guide. Just one alert for other builders to check re the head bolt instillation. From reading some of the forums (on confusing instructions in the RE service manual) the use of the 270 degree angular torque method to tighten the head bolts is an alternative method to using the conventional two stage torquing of the head bolts with a torque wrench. Doing both together may over stretch the bolts. Hope that helps.
I am not sure how the 270 angle torque would work without first doing the normal torque. There would not be a starting point, or you would have bolts that only have 3/4 of turn total. Revelry Racing uses both on their video build. It is pretty standard on vehicles to do normal torque and then angle torque for head bolts. I didn't think the manual was unclear. I double checked it just now. I think the manual is probably correct.
@@OakInch Yes - that's a logical point. Better get one of those angle torque meters then!
great video good explanations
Thank you!
loved it
Beast!
I have thought about a bespoke adventure tourer. Grease nipples being put in like the old bikes so you could use a grease gun on places like the swing arm bearings or bushes, steering head bearings or suspension linkages for examle which would save stripping the swing arm for example to grease stuff. Clearly its not done nowadays to save costs but you could drill a 5 mm hole to fit a m6 thread grease nipple by tapping a thread then screwing in a m6 thread grease nipple with a ball bearing to stop the grease coming out which is great engineering saving busges and roller bearings going dry. Rubber gaiters on fork tubes save dirt and moisture getting into seals so they last longer
Great instructional video! You need to replace the stock header pipes. Makes a big power difference.
Thanks! I actually did replaced the headers in this video. Unless you are talking about getting a different head with bigger openings. I may actually get one from revelry racing in the future. I don't know yet.
Well done buddy
Thanks!
I loved your video, enjoyed it...got inspired to next level..enjoyed every aspect...just a thing missed in the video...we all were very excited to hear bike after such big upgrades, especially that bore upgrade..but we didn't goy to hear that sweet sound...
Then i checked your videos for that sweet sound..but found no more RE videos after this.. atleast please do a sound video of this..
It is coming. I only was able to put 500 miles on it before it became too cold to ride. I wanted to get it fully broken in before doing a review, but I will probably do a quick talking review soonish. Then I will do one riding it when the weather improves. It sounds good and runs great.
parabéns pela aula, será muito importante para mim aqui no Brasil.
After a year how does it run?
Great video and I love how you have the Cafe racer spirt and get rid of all the extra stuff and make it better
Thanks! It runs great. It gets some stop light love occasionally too.
If you have any input on what could be done better, please share in the comments. The bike is running great. What you see here resulted in a successful outcome. But any helpful input would be appreciated by myself and anyone else trying this. I will address things I was asked about in this thread.
1. The clutch is correctly installed in this video. The instructions for the Recluse Clutch install are in the description. The clutch plates all go into the same slot for the Recluse Clutch, where they are protected by the safety clips, as shown. They do not use the smaller outside slots. I did remove a comment from someone who claimed otherwise, despite the safety warning in the instructions to make sure they all go in the same slot. Having a safe and working clutch is too important to really entertain the debate. But, if you had any questions about that yourself, I refer you to the link in the description so that you may gain piece of mind.
I would suggest, inserting the pistons into the barrels first with the inner circlips fitted. Then fit to the con-rods.
@@chrisminter271 After what I went through trying to get the pistons inserted, I would definitely find a way to give that a try next time.
@@chrisminter271 Hey Chris, I posted a follow up video with some information and a review.
You're my new favorite channel. Been itching for this bike and I think in January I'm sure I'll get it done. Is that 150 as wide a tire the stock frame rail will accept? It looks slick!!
It is only one size up. I have heard they can go 2. But I cannot confirm.
@@OakInch you rock.... thanks Superstar.
For all that you could have simply looked for a 1200 Thruxton, the RE is fine stock but it's done now, show the dyno read out. Great job anyway, I help in the builds on Street tracker 790/865 old aircooled Bonnevilles and Scramblers, we do the same thing but 904/995/1200 kits. 100-110 ATW.
Cool. I am sure you are better at it than me. There is actually a video where I show the dyno readout on my channel, after a few more changes and a tune. It shows stock, vs what was expected with upgrades, vs what I achieved. I do have a second bike. This one I can't stop working on for some reason. I think I might be possessed.
Very helpful video, thanks! Will need to tackle this next year. Can you let me know what exhaust cans these are?
The ones I started with are the Barrel Atom exhaust slip-ons. The ones I ended with are part of the Diablo full exhaust from K-Speed.
@@OakInch thanks, which is more preferable on sound?
@@xenoark2849 The full Diablo exhaust is way louder. They both sound really good. Also, the DNA air filter and filter cover removal upgrade changes the exhaust tone quite a bit. I was pretty happy with the barrel atoms, the DNA kit, and the fueling plug. It was raspy and cool sounding. I guess it depends how much you want to get ahead on the upgrade cycle if you plan on doing more. You'll probably need to get a Power Commander with the full exhaust. That would be two things out of the way.
Yes i have all mods done including power commander, have scorpion cans for the past year but not liking cone style although sounds is great, prefer looks of yours - Barrel Atom. Will have to look into them. Next and last mod is big bore on the list
Love your content, I myself just bought a Continental GT 650 here in Brazil, and your content is really valuable.
I just need to say one thing: as your content, your voice also is good, so please, stop trying to thicken your voice , PLEASE. It's really annoying, reeeeally much more annoying than your real voice.
Don't mean to be rude, just being honest. Your voice is beautiful, stop trying to change it.
Your content for sure will be more appreciated no doubt.
Keep up the good work.
Thanks! But I am not trying to change my voice. I am not really sure what you are hearing other than fatigue and different acoustics. It is nice to know I sound good. I have had to go back and make sound louder, or do a voice overs on different devices, when the sound quality was terrible. But I do not think I had to do it on this video. Those sound a little sped up sometimes.
Great video! Regarding the O2 sensors....I read somewhere that if you are going to disconnect the sensors you should pull them out because it can ruin them. Not sure why or if it's "fake news" but I removed mine on another bike just to be safe. SS plugs are not crazy expensive for piece of mind.
Maybe I will pull the O2 sensors off the original exhaust pipes that I replaced, and store them separately. Not sure why it would matter. But, I don't know what I don't know. Thanks!
@@OakInch No worries...I look forward to hearing more about how you like the mods you have done. I bet it makes a HUGE difference in the increased fun category.
@@adventuristnw2321 It certainly does.
Next time mate. Drop the entire engine and lower sub frame to do the mechanicals. A lot easier. Great vid tho . 👍🇦🇺🥃
Does the valve shims comes with the Bore up Kit ? Why do we need to do it?
The shims come with the cam shaft upgrade kit to allow the valves to adjust to the different shaped lobes on the new cam. They are not part of the big bore kit.
Put a short 1/8" piece of a plastic straw around the keepers until you back the compressor off
Is there any requirement to add extra engine oil since the bore is big ?
Not that I have read or heard of.
Why didn't you do the air delete kit when you had the head off?
I was waiting for some RE tools to arrive to do the big bore kit and cam. I wanted to make some progress. It was one more thing off the list.
How much difference in power vs stock? and is there a difference in top speed?
I think stock they are about 40 whp at the wheel. Mine was 66 WHP at the last dyno tune. I'd say about 50% more HP after all mods, including air box removal and a tune. The speed is limited by the RPM limiter and gearing. You can't really make the top end go higher with a big bore. But you can hit the top end a lot faster. You would have to change your gearing on your sprockets to get more top end. I have a 16 tooth front sprocket in right now, stock is 15. It will do 60 mph in 2nd gear, just barely, before the RPM limiter kicks in. I had a 17 tooth sprocket for a while that made it less torquey. But I could cruise at 65 in 4th gear, at about 4500 rpm.
Right now, in the real world, I am getting a 4.23 sec 0-60. A stock is going to be over 6.5 in the real world.
I have some other videos of what I did after this work to get it to its optimal state. This video wasn't the final result.
Where did you get the single seat?
MK Designs India
Muy buenas; podrías decirme de dónde es el sillón y si cortaste el Chasis?
Gracias
Mk Designs India. The tail tidy did require having the rear of the frame cut.
@@OakInch gracias!!!
How long do they say the break in period of not exceeding 3500rpm's is?
Here is the initial plan I followed based on the instructions: First 50 I stayed under 3500. Next 50 I stayed under 4250. Next 50 I was mainly under 5, with some runs over to 6k. From 150 on I started doing higher RPMs in burst.
@@OakInch that's not too bad. I thought it was somethin like a couple hundred miles for a break in
@@motomitch The full process goes to 1000 miles. After 500 you can ride like normal. The last 500 you really just have to not hold one RPM for long periods of time on the freeway. Varying the throttle lets oil move around in the cylinder. The instructions come with the big bore kit.
What handle is that can u send me the link please
They are the Diablo Handlebars from K-Speed.net . www.ebay.com/itm/276205728407 is a link to where you can find them. I have the chrome ones. There are a lot of people selling them so look for the best price. K-speed.net has high shipping prices, so I would try to get them off of ebay or somewhere else.
Only THREE springs ? 😱
Can you share the buy link of the seat!
This is the seat: mkdesignsindia.com/product/caferacer-seat/
@@OakInch thanks bro no need of cowl! For convenience!
@@SatnamSingh-ke7rb No problem! I am also using their "full length" tail tidy.
Couldnt you have bought the S&S parts and power commander much cheaper in US? They are made in US
I looked at their website to try and get the big bore kit. But they didn't have the complete kit at the time. They only had the one where you had to machine the cylinders yourself, which is cheaper, but requires hiring a machinist and doing a bunch of extra stuff. I still do not see the kit there as of now.
@@OakInch well glad you looked into it.
Well.....let's HEAR it...
You remind me of Savagegeese
Good video,
But where's the Royal Enfield signs on the side of the bike?
Sorry but unless you haven't finished it yet
It looks very Slack?
Royal Enfield have more Provenance than Triumph,BSA or Harley Davidson,
You should be Proud to Own a Royal Enfield 👍
Cheers Paul
I did a video a while back where I repaired and repainted the tank. The emblems were removed then. I do have some replacement stickers. But I think it looks good all black. I never ended up using them. Maybe I'll check Red Bubble for some new RE sticker designs. The side panels are no longer on the bike after I removed the air box. But I had already removed those stickers to match the tank. I don't know what slack means in this context. I think the only place its says RE at the moment is on the engine itself. I do like putting stickers on bikes. Haha. We will see what happens.
@@OakInch
Yes,
Sorry I'm from Yorkshire Great Britain,
"Slack", for us is slang for something that is not quite right,
I've really enjoyed watching your video,
I own a Royal Enfield Interceptor 650 and a Hunter 350
I've been riding motorcycles for 50 years,
But got inspired by watching RUclips videos to do my first service on my Hunter,
I've always done Oil and Filter change's,
But I really enjoyed doing the Tappets on my Hunter,
I'm a frustrated mechanic I'm sure,
Again, great to watch your video,
I'll be subscribing to your channel I'm sure 👍
All the best from Yorkshire Great Britain,
Cheers Paul 👍
Great job can I send you my RE 650 you do the same for me same everything
LOL. No. Once was enough.
You mean to tell me that you have been running an Enfield twin and you haven't had any electrical problems? I'm on my 4 th regulator, 2nd battery, I've never had such an unreliable new bike.
I did a video on the issues I had in the first year. I think I included a new battery, and a few other issues. Engine is pretty solid. However, when I get on my KTM 690 SMCR, the quality difference is noticeable. Haha. So far nothing has happened that I couldn't fix, or that outweighs the enjoyment. It would probably annoy me more if it was my only source of transport instead of a project bike. As it is, it runs well and gets the stop light love. According to Conan the Barbarian, that is what is second best in life.
What tires are those?
Perrelli Sport Demon Front Tire 110/90 r18 amzn.to/3QSYFbG
Perrelli Sport Demon Rear 140/70 r18 amzn.to/3LDyXap
I took the wheels to cycle gear and had them installed. You can get the tires from them also.
@@OakInch Are they still tubed or did you seal the rim?
@@nonielacuesta2735 Still tubed.
@@OakInch thx for reply, do you think I will need a new tube if I got 150/70?
@@nonielacuesta2735 I got new tubes. I suppose it is probably a good idea to just do it.
Enclosed chain and sprockets would mean drive chains would last 30000 miles rather than 10000 miles.
Why are you not meant to start this up on a stand?
I think it is just a general safety thing I heard or read somewhere. I am now questioning whether it actually matters. Haha.
@@OakInch :) thanks for the reply. Lovely bike and well constructed and informative video. thx
Wow you really devalued a nice bike. I would never buy a used bike that has been modified
Prepare to be flabbergasted, astonished, and infuriated as I continue to modify this project bike to become faster, lighter, and cooler.
@@michaelmurdock4607 Thanks!
Somebody needs to answer that phone
All these woman want to date a guy with a motorcycle. I can't be getting waylaid while I am working.
@@OakInch dude u r funny. nice to meet u