Biting the Bullet

loss screw. Further disadvantages of

crankcase gas build-up are increased wear on
All internal combustion engines will develop a the
pressure buildup within the crankcase unless engine
some kind of venting system is provided. This due to
pressure build-up is the result of two the
processes. The first process will occur
irrespective of age or condition of engine and
is the result of the piston downward
movement during the compression stroke
compressing the air within the crankcase.
The second process is known as “blow-by”
and while possibly in all engines, is more
pronounced in older and worn engines where
combustion gases leak
What’s that Quacking? past the piston rings
and into the corrosive nature of blow-by gases, the oil/gas
The duckbill breather tube crankcase. Irrespective mixture causing increased drag on moving
has been known to give a of the process by engine parts and the oil scavenge pump
distinctive “quack” as air is which it is caused, a performance degrading as it pumps gas in
expelled from the crankcase.
pressure buildup in preference to oil!
This can be particularly
evident during shutdown.
the crankcase is not a
This is normal and shouldn’t good thing. Even a In the past it was found that a simple one-
be of concern to the Bullet slight increase of way valve venting crankcase gases to the
owner, although some crankcase pressure atmosphere was an effective means of
people do complain that the above that of the overcoming crankcase gas build up. Early
noise detracts from the atmosphere is likely to Bullets were provided with a simple rubber
classic thumping sound of result in leaks from “Duck-Bill” hose fitted to the left hand side of
the exhaust! any weak gasket or the crankcase, just below the cylinder head.

1
Biting the Bullet

result is two different systems. The first

system has a “catch can” arrangement

Figure 1 - The duckbill breather tube [photo

credit]

located beneath the battery. The original

Figure 2 - The Duckbill venting to the atmosphere
above the chain [photo credit]
duckbill breather tube feeds into this catch
can where the vapour in the expelled gases
are condensed. The catch can is vented into
the right hand tool kit, where it is drawn back
into the engine through the air filter
arrangement. This system is effective and
actually draws gases out of the crankcase,
helping develop a lower than atmospheric
pressure.

With increasing constraints placed on

manufacturers of motor vehicles, the Bullet
in recent years has been subject to
restrictions on crankcase gas emissions. The

2
Biting the Bullet

The problem with this system is that the

catch can does fill up with condensed liquid
(water is a by product of internal
combustion). Fortunately in this arrangement
the catch can is provided with a drain plug to
empty the contents as part of regular
maintenance. If, however, the can is not
emptied regularly it is likely to fill up and
spill the overflow into air filter.

From 2004 on, the Bullet engineers

Figure 3 - The expelled gases from the catch can are recycled
through the left hand toolbox [photo credit]
implemented an entirely new solution. The
crankcase breather was relocated from the
side of the crankcase to a position directly
behind the cylinder (some models with this
arrangements will still have a cast but un-
drilled breather outlet on the left hand side).

3
Biting the Bullet
This latest system copies the catch can
approach of the previous models, but now
relocated to behind the battery and below the
seat. There is also an additional tube from
the bottom of the catch can to return the
condensed oil to the engine through the
timing chest. This system provides no easy
drainage process for the catch can as the
build up should be far less than the pervious
catch can arrangement.
Figure 4 - The post 2004 Arrangement showing
the oil return tube to the timing chest.
4
When Things Go Wrong
Under normal operating conditions the
crankcase breather system shouldn’t cause
problems. However, when the Bullet is run
on cold days and for short periods the oil
does not warm up sufficiently to “clear” the
condensation through the breather pipe,
resulting in a build-up of milky residue. If
this is allowed to continue the residue may in
fact block the breather pipe. On older bikes
without the oil return hose to the timing
chest this problem will rectify itself as the
engine temperature increases and the tube
clears itself. On newer bikes with the return
tube, the blockage in the breather is likely to
result in the engine venting itself through the
oil return hose. This further exasperates the
problem and results in oil buildup in the
catch can itself and potentially a spill over
into the toolbox and fouling the air filter. This
not only causes a mess, it is likely to result in
the bike running too rich with a subsequent
fouling of the sparkplug and carbon build up
on the cylinder head.
Modifications
Biting the Bullet

Removing the catch can System Entirely From Royal Enfield USA

Tempting for some, but probably a breach of

environmental protection laws in most
countries.

From the Head Office in 1958 …

Figure 5 - Royal Enfield Oil Re-circulation

Modification

Royal Enfield USA provides an oil

recirculation system for older model Bullets
with only a duckbill breather venting system.
The modification allows oil from the breather
tube to be redirected to the engine via the oil
fill cover. The system can also be fitted to the
original catch can for bikes without the
return oil tube, preventing the catch can
filling on Bullets without the oil return feed
tube.