- Wed Jul 25, 2018 11:49 am
#78145
I'll add that when I was having trouble with the 4-speed box on my 350 bullet which got progressively harder to find first, then started jumping out of first, I landed up finding more than one problem. The ratchet mechanism was pretty worn so I swapped that out which helped a little but not much. I eventually "bit the bullet", drained the grease and stripped it properly. I did this with the box in-situ on the bike.
I found two things, the first was an horifically bad fit between the sprung detent and the selector arm which I fettled with a hand file (this being a precision piece of engineering equipment to whatever they used to fabricate the part initially. I suspect the factory employs a blind guy with one arm and an angle grinder). The second was extensive chipping of the dogs on two of the gear clusters, which I replaced.
This all sounds like a huge amount of hassle to fix but was, in reality, a total of one afternoons work. The worst bit was cleaning all the stinking grease off every part I wanted to work on. The box itself is not a complex piece of machinery. I took plenty of digital photos as I dismantled it in case I forgot where anything went but as I recall, they were unecessary. None of the parts are particularly expensive either so if something looks worn/dodgy, just swap it out.