Hitchcocks Forum

I needed to replace the gearbox pawl,(2000 Bullet 500), old and new compared.



The grease was well past its best, and contaminated with the pawl metal dust so it was out with the gears and a complete clean up. The next pic on the right shows the inner cover prior to its clean, it looks like black Moly grease, maybe it was, who knows what previous owners have done to it.



Putting it back together was a chore, and that ball-bearing from the clutch push rod also made a bid for freedom. I will be hunting for it later with a large magnet.

I put a dollop of black molly in with the 00 grease. Makes for a better gearshift than just the grease.
My word, you did need a new pawl! I'm surprised it was engaging at all.

They go together very easily, I leave the mainshaft out, then you work the mainshaft sleve with the mainshaft gear on it past the selector fork and then lift it up and push it through the bearing, making sure that the mainshaft gear is fully facing you and the mainshaft sleve is sticking out the rear of the box the right amount for the distance piece and sprocket to fit. The rest of the gear clusters are then fitted sitting on the bottom of the box and with a bit of fiddling and moving the sliding gears the selector fork will fall into place and then you angle the layshaft up slightly to get it to enter the rear bush. Then I fit the mainshaft