By jacobtue
#86025
Hi all... after many thoughts I've decided to convert my 2003 Bullet 500 gearbox from 4 speed to 5 speed. I want to keep gear shift in RH side. Is it correct understood, that I can do this conversion by only substituting the clutch basket apart form the gearbox itself, or do I need to do any other modifications to the clutch/primary drive?... regards Jacob
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By Wheaters
#86026
I'm in the process of doing this conversion for my 350, see my thread about off roading a Bullet. The Hitchcock catalogue has a picture showing the parts needed, including the clutch basket.

On the primary side you will also need a new gearbox sprocket if not included with the gearbox you buy. This is because the splines are different.
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By Wheaters
#86028
Oops, that should have read "not including" the clutch basket.
By Daiwiskers
#86030
I have the close ratio mod from our host's fitted to asbo 30 it has made a tremendous difference first is now a usable gear and the big jump from 3rd to 4th has now gone now if it runs out of steam in 4th I can change down without it over revving
Food for thought it's a cheaper and easier mod
Just an idea Dai
By PO51UHD
#86031
I did the 5-speed conversion on my 350 and went up one tooth on the gearbox sprocket. Best thing I ever did. In addition to the parts already mentioned I seem to remember you’ll also need a different seal and carrier inside the chaincase behind the clutch as the gearbox input shaft is a different diameter.
Good luck!
Stephen
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By ed.lazda
#86032
Mine came with the 5-speed box and I converted my wife's Bullet. If you're buying new, Hitchcocks do a complete kit that includes all the parts you need, including some slightly longer studs and the clutch centre.

Expensive, but if the bike's a keeper, definitely worth doing.
By Andy C
#86034
ed.lazda wrote:
Mon Oct 14, 2019 8:18 am
Mine came with the 5-speed box and I converted my wife's Bullet. If you're buying new, Hitchcocks do a complete kit that includes all the parts you need, including some slightly longer studs and the clutch centre.

Expensive, but if the bike's a keeper, definitely worth doing.
Ed - I'll second that, definitely the best thing I ever did to my 612. Roll on spring 2020.....
By jacobtue
#86044
Thanks for all replies...I do think it's a costly thing to do, but my bike is a keeper, and the reason I've decided to do a true 4 speed to 5 speed conversion instead of improving the 4 speed box on the bike. So in general terms I "just" need to substitue the gearbox itself, the gearbox sprocket and the clutch assy, if I understand it correct?... regards Jacob
By PO51UHD
#86048
Jacob
I wrote up my 5speed conversion in RealClassic magazine - it appeared in the November and December 2018 editions.
If you can’t get hold of a copy, email me at stephen_herbert(at)btopenworld.com and I’ll send you the text of the articles plus a few key photos...
By mauri
#86052
here's en easy list of the parts needed to replace the 4speed to 5speed.

PART No. 550111
STUD, 3/8'' x 5.3/8'' x 26tpi, 5 SPEED GEARBOX BOTTOM X 2
(maybe M8 on some later models)

PART No. 550501
CLUTCH CENTRE AND BACK PLATE, 5 SPEED (550503)

PART No. 550116
SEAL AND ADAPTOR PLATE (BEHIND CLUTCH), 5-SPEED

PART No. 144624
GASKET, CLUTCH OIL SEAL (140937)

PART No. 540070
CABLE, CLUTCH, MINDA, 5-SPEED, 2003-2007, NOT ELECTRA X or T/BIRD or EFI, INDIAN MADE
(may need to moddify the brake lever, may need to take cables out of eyelet in the casquette to get cable to pass true)

PART No. 550145
BRACKET, REAR MUDGUARD, 500cc 5speed + SIXTY 5

PART No. 560052
GASKET, CHAINCASE, ELECTRIC START MODELS ONLY

PART No. 144621
GASKET CHAINCASE, KICK-START MODELS ONLY

check oil level in gearbox!!

to modify to right shift, additional parts are needed

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