Forum

[Bertie the Bullet]

Took a much needed day off work today and put about 150 miles on Bertie's clock steering him around the Kent coast, once he had had a good run and everything had warmed up the gearbox became problematic, especially when changing down from 2nd to 1st, could this be the selector unit is worn, if so which bits should I be looking at , answers on a post card please ?,PS 2004 500 Bullet 4 speed Albion box. Thanks in advance.

[Les]

I think I must have spotted you in Hern Bay today about 1 o'clock I was working there and as I was leaving the toilets on the front I heard a bike and thought it sounds just like an Enfield looked round and it was, a bit envious as I still had a few more hours to do before I finished.

[PeteF]

It's usually clutch drag that causes the problem if it gets worse when warm.
If it clunks into 1st from neutral then the clutch is dragging.
Cures?
Correct adjustment of the clutch lever/cable/actuating arm.
Elimination of gearbox cover flex.

[Bertie the Bullet]

Yes Les that was me, you could be right Pete however even with the clutch adjusted correctly it still plays up when warm, I thunk some new bits are in order.

[PeteF]

Mine did exactly this until I fixed the flex
Mr H now sells something similar if you don't want to make your own.

The flex on the end of the gearbox is only a few mm but makes a big difference.

[Gwilly]

Hi Bertie, I have the five plate conversion fitted and i found that the drag problem was aggravated by the three heavy weight springs supplied with the kit..

Heavier clutch action leading to more flex, Great if your pulling a chair or suffering clutch slip but i think overkill for a standard motor ridden solo..

I found a new set of standard light springs gave a light clutch which won't slip under normal acceleration and less likely to overheat and drag..

Also removing all slack from the cable, even slight tension to a point where any more would cause slippage allows neutral and first to be found at standstill..

Last three years i've used nearly the full litre of ATF in the primary case, Just my theory that the more fluid in contact with the clutch and casing the better the heat transfer from clutch to air..
Not proven of course, just a whimsy... Also clean the plates every oil change with petrol as they do become sticky with old oil and friction material.

Lots of grease on the pushrods and actuator assembly as well, worth checking when you next have the outer gearbox cover off as the bearing cover plate had cracked into two pieces on mine and i'm sure this had an effect on adjustment/clutch lift. Have a good summer and beware of volvo man or anyone wearing a flat cap...

[ed.lazda]

You obviously NEED a new English made 5-speed gearbox. URGENTLY.