[sandeepmohan]

Its a good thing you asked me to strip that air box for you and post pictures. I got a shock at the rust on the filter mesh. Here you go mayte....Oh and some comments from my friend who owns the other 500 in the pictures.

""The part that guy was referring to in the filter box i dont think is a resonnator of any kind.. in fact the same type filter were used on the old A350's before the filter was shifted to the tool box. I feel its basically reduce the volume of air sucked in since the bike would run rich/lean for a 500 due to the engine size and for the a350 due to the higher rpm .Its only a kind of narrowed down intake since the old 350's air filter box was bottomless.
The new bikes resonator box is for emission/effiiency basically and also runs the bike much smoother. I had run my 350 with the old type box filter and could make out the difference easily.
The extra oil pipe or the breather pipe has one more main purpose. one is what you mentioned,to store excess oil.The reason it ends in the air filter box is because the engine pumps out toxic fumes through the breather and for emission purpose those fumes were routed to the air filter box so it could be sucked back in for combustion for which the downside was what u mentioned when the oil overflows.

As far as i know , the air filters were shifted to the tool box the same time the exhaust pipes went condom size! the long ones..

Thats about wat i know with experimenting with diff size filters on both the bikes""....by Anil Tharian

[Rennjit]

Thank you Sandeep for detailed pics & feedback too. 'Resonator' was only a possibility from the part sketch-list where that filter mount pipe seemed to be of rubber. Newer CI bikes do run smoother with the big filter in tool box but takes away a full storage compartment!
Hope its easy for you to get a replacement filter element and while at that could you please check if a box is available. This box is better than old open bottom ones for sure.

[sandeepmohan]

I will need time till the next weekend to know about its availability. I have a regular shop for RE spares but asking over the phone may not work out & visiting the shop during a weekday is not possible.

[sandeepmohan]

This filter box in not available. I went to the store and they had a filter box twice the size of this & is not a genuine RE part. It was not possible to take a look inside it. I have seen this over size filter box. Its mostly chrome, you spot it on some older 350cc variants as retro fits.

I did replace my air filter though but it was hell doing it. The screw alignments have changed so I could not fit it as is. From the images you can see a rubber end piece on the filter unit. RADIANT is written on it. I ripped both these end piece and fixed it onto the new filter. Its the only way you can replace the filter element.

[jingaboysr]

My CI 500 is 1995 model, so RE definitely produced CI500s in '95 as well. I am pretty sure of it since I took the fitness certificate last year.

IIRC, I had the same air filter box and filter as the CI350s, I don't remember any extra equipment below it. But again, it's been long since I moved to K&N and the stock filter is lying at home. I'll take a look tomorrow.

AFAIK, the only thing that differentiated the pre '96 models and post '96 ones are the PAV setup in the later models, due to stricter emission norms. (Of course there were later ones with disc and self start)

[jingaboysr]

Here are the pics of my air filter. That extra thing at the bottom part is not there.

So it looks to be something for the PAV system, i guess.

[Rennjit]

@sandeepmohan, i saw the same box at parts shop(~rs 600). See the pic, it is real big in comparison to others & has an open able top piece, even the filter (~rs 100) is as big as newer tool-box round filter. Might be wrong but i think old type (pic 2) filter would be a direct fit in your box.
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[sandeepmohan]

@jingaboysr: Whats a PAV setup & whats that transparent breather pipe running from the filter box? I have seen this pipe but never really understood why it existed. Your filter is mounted with 1 single center screw.

@Rennjit : Thats the exact same filter I saw at the parts store in Bangalore.

[jingaboysr]

I have no clue where that transparent pipe from the air filter led to, and I can't verify it since I've moved on to a K&N a year back.

A wild guess is that it led to the connection between the engine and the carb, there was also a adjuster screw there IIRC.

As far as I know, PAV was mainly to control emissions, supply more air to the cat con.

[bradhey]

this transparent pipe connects on a inlet manifold near the caburetor. It allows to add more fresh air (as in the case of high altitude) to make the mixture lean, if needed. It's screw is barely adjusted in plains, but may be quite useful up in the hills.

[sandeepmohan]

@bradhey : Thanks very much. Very useful information. I now recall where this rubber pipe travels

[trammway]

Originally Posted by bradhey

this transparent pipe connects on a inlet manifold near the caburetor. It allows to add more fresh air (as in the case of high altitude) to make the mixture lean, if needed. It's screw is barely adjusted in plains, but may be quite useful up in the hills.

I was thinking that inlet manifold near carburetor is connected to the exhaust pipe's small outlet near to the cylinder for emission purpose. As my RE500 exhaust was in altered condition, I didn't have this setup in exhaust but I did find the inlet manifold with a small pipe poppling out (at present I blocked it to avoid dust getting into the cylinder directly, I saw this small tube in open condition after my engine was seized in Gingee)

The picture of exhaust pipe with small vent from one of the RE500 I have evaluted is posted here with a green circular mark.

[trammway]

Dear TBHPians,


I think I have associated myself with a big white elephant which is also sick like anything.

After spending a lots of money after the seizure on the day one of my purchase, I was riding the bull under 60kmph speed for 1000kms.

I observed few items for change: Rocker, Silencer, Speedo meter and Oil pump.

You must ask me, why am I very particular about these items. The number one reason till I close 1000kms on the odo, the rides were really good as I always maintained below 60kmph. After crossing 1000kms I thought of pushing the bull to a little high and you know what? I started getting that old vibration issue. This time I came down below 60kmph to save remaining parts on the bike.

I went to 2 big bull mechanics in Chennai to take opinion, so the following ideas:

1. As I have completed 1000kms the oil service could be done

2. Rocker and push rod needs to be checked

3. The silencer needs to be changed (suggested by the mechanic after riding my bull. He stated lot of power loss as the exhaust is not actually flowing the smoke out creating a jam). This could be another reason for the vibration as well.

Alright, as I have got the tigers tail I need to know try these options. So took the Bull to Chezhian (ex-bullet dealer service personal at Triplicane) to change the rocker assy.

For my surprise, I found that the push rod is bend hence I bought a new push rod aswell. As everyone was telling me to revert the silencer to original spec, I decided to stick to time tested goldstar model. But with my current bend pipe nothing going to be possible. Hence got OE RE500 pend pipe for Rs.3100 from chennai shop. My mechanic lend me his Goldstar silencer made by some bangalore company for testing purpose. I'm currently riding the bull with the Goldstar and stock pend pipe. The sound is amazing and the pickup is really changed a lot, but my mechanic still suspects pickup is not at par with RE 500 mark.

We changed the oil, rocker, push rod, oil filter and oil pump. As you all know my bike runs on RE 500 brand new cyl kit and the engine is serviced with all OE parts just about 1000kms before.

Now while I push my bullet about 70kmph, I'm getting that worst vibration and I'm clueless for any solution.

Does anyone here have some remedy for my problem. The following are non-standard in my RE500

1. The rear shocks are gas filled ones
2. some cosmetics

I have validated that the oil circulation is much better now, the vibration comes only when I cross 70 mark but with in 70kmph speed my bike runs like heaven. But unfortunately I couldn't even over take a TVS super XL moped till date. What a shame and I really disappointed the way I got into this messy RE500.

[sandeepmohan]

I don't know what these vibrations are as I have not ridden a 500 with just 1000km on the odometer. What I can tell you is give the bike another 2000km on the odometer and then take it slowly beyond 70kmph. Do not change the oil. Just check levels and do the next oil change once the bike shows 4000km on the odometer. You did not mention if the oil filter was changed when you got the first oil change done. Not that it will reduce any vibration but still.

If all this running in does not work, there is some serious component mismatch in the engine that is causing the vibration.

You should check if this vibration exists if you rev the engine freely when in neutral. There is no load on the engine when you do this.

[BulZire]

Console yourself Siva sir,

I would suggest you to check the chassis and engine mount bolts and clamps once again to make sure nothing gets loosened on the run. It might be a weird suggestion but this check made me to sort out a minor vibration in my bull.

Since you had already done up everything from engine perspective, do also get the oil filter and carb cleaned to make sure no dust stagnates and stops the free flow of fuel or oil.

In other case start the engine and close the exhaust mouth with something. Then revive it hard while on the stand/neutral to check if there is any vibration from the engine mount.