Forum

[Norm]

 I don't want to tell the Hitch boys how to suck eggs but this is where I think they went wrong, when I converted my shifter I extended the shifter shaft out the back of the box as well so it went through the inner seal in the gearbox and out through the outer seal in the new shifter position. This meant that all the work could be done through the outer case with no thought of having to remove the motor to fit a plug. Once I had made up the bits it probably took me a couple of hours

[Alan R]

Nice one, Norm ----------- plus the new shaft is now fully supported. Do you facy a job at Chadwick End ??

[Freddy W]

Hi Norm


How did you convert the shifter shaft? Did you weld a bit of the old shifter shaft that was removed, and if so how long was it and how did you get it true?

Regards Fred

[Norm]

 Hi Fred,


   You are right, I cut the original shaft that goes through the engine cases just long enough to go out through the seal in the gearbox, not that critical as long as it goes through the seal, then I cut the splined end off the other end, long enough to come out through the outer cover, put it in the lathe with the splined end in the chuck and welded it up. Make sure your earth is not pulling through the lathe's bearings and you won't have a problem. I made up a long drill bit to go through the cases to give me the centre of the shaft in the outer cover, but a pointed shaft like a centre punch would do a similar job. Just sleve it so it is a snug fit through the cases. I then fitted an oil seal in the outer cover and all fixed 

[Alan R]

Hi Norm ----- Would you like to swop your "plugged" 5-speed outer primary chaincase with my standard 4-speed outer chaincase ? I already have a 5-speed inner chaincase and would be able to continue with "Plan B"-----the Bullet Sixty Five deal fell through. I'll pay for the P&P if that helps ??  

[Alan R]

TYPO !!!!!!  Sorry Norm. That last post should be addresed to }--------------------- Freddy W.  I could do with the outer primary cover off a 65 because it has the shaft hole and seal recess already in it. My bike is a 2006 Bullet Classic 500 iron Barrel.  

[Norm]

 Alan,


     I forget what plan "B" was, so many options it all got too hard, but I assume now that you are talking about primary cases you are contemplating fitting a five speed. And my outer primary is no good to you because mine is an Electra X one And remember if you do change to a 5 speed you will need a 5 speed clutch hub and also fit a 5 speed oil seal to the inner primary case. And you will need a 5 speed clutch cable and you might as well hook up the neutral light. Not sure if you would have a wire for it but you need it with the 5 speed because unlike the 4 speeder no neutral finder. As for the sheet of plaster with all the measurements and drawings on it, do I  throw it out?

[Alan R]

Hello again, matey !! Yes, so many "changes" ( groan !!!) been going on, hard to keep track---and it's me doing them as well!! OK, this is the current state -of -play }----- I can't afford a 5-speed g'box so that option is a non-starter.( plus all those other reasons you just mentioned as well). So, leaving the 4-speed in situ, I can either ------a)  Explore the possibility of changing from 1-up, 3-down to the other way around using things like a small epicyclic adapter between g'box and pedal, and similar  OR------------b) As I already have a Bullet 65 inner chaincase then using that to align and back-drill through the oil tank to replicate the 65 set-up ie Left foot change. We discussed this earlier and you were good enough to give me some dimentions regarding a tube going through the tank?? I would also need the shaft to exit my outer chaincase--hence my interest in Freddy W-- we could help each other out here.  Which ever option I eventually use it will include our hosts full upgrade kit for sealed bearings, closer ratiio etc.  I would prefer "Option B" to match the rest of my bikes but "a)" I could live with---only a 50% re-think on the move. 

[Norm]

 Alan,


  Before you waste any more time on this what you are trying to achieve won't work, thinking of running the shaft through the motor for a 4 speed is impossible, the 4 speed gearbox entry point with the left shift is at the rear of the box, the 5 speed is at the front. This is the reason for that abomination of linkages the left shift 4 speed had

[Freddy W]

Hi Alan R


Sorry no swappsy. I think I will stay with the 65 left hand gear change. Even with all the super instructions it seems a bit of a hassel to change to right hand change. Also have not got welder or lathe.  Thanks everyone for all your comments & you all have a good riding summer.


Regards Fred