There is a lot that can be done to improve engine efficiency.

There are radical technologies like supercharging and turbocharging; as well as specialized pistons, valves, heads etc. Problem was, none of these are available on a small diesel generator engine, which is what powers this Royal Enfield diesel conversion.

Instead we chose to do the following:

"Pocket Porting"

As fuel travels into the head, and exhaust travels out, the paths they take are irregular and generally not very efficient. The rough castings of the engine itself, the drilling and boring techniiques used to create the head, are all done for maximum cost efficiency and often result in much lower efficiencies than those theoretically possible.

So we took the head and "ported" it, grinding the intake and extake areas smooth and cutting away unnecessary metal to make the air swirl in - and the exhaust swirl out - as smoothly and efficiently as possible.

Ceramic Coatings

Then we completely coated the engine - head and body, piston head, valve heads, bearing surfaces - with specialized ceramic coatings - several different kinds. On the bearing surfaces, they were coated with a coating designed to reduce friction. The engine interior and the head interirors were coated with ceramic materials designed to throw off heat.

Balancing and Shaving

To reduce weight, we shaved off most of the fins of the flywheel, and cut some of the "meat" out from the inner surface of the flywheel. A flywheel on a generator engine cools tne engine - something we didn't need because on a motorcycle, the air moving past will cool it sufficiently.

Then we balanced the entire drive train assembly - piston, con rod, crankshaft, and flywheel - to within a couple of grams, so that it would create less friction through vibration as it turned.