Forum

[klutz]

I wish to remove the inner chaincase from my 2003 Bullet 65. Other than requiring 3 different pullers and a rotor shim, is there anything else I need to know about this job before attempting it for the first time ?
All advice gratefully received.
Many thanks

[Norm]

Klutz, only thing if it is an electric start you could have problems getting the screws out that hold the inner primary to the crankcase

[Norm]

As for 3 pullers I usually only need the clutch hub puller, rotor usually comes off as does the engine sprocket without any problems

[Leon Novello]

Others will advise later about the rest, but you can make a rotor shim from a plastic 2-litre milk bottle, they usually give the correct air gap. Cut into feeler gauge size strips or one long strip wrapped around the rotor. Oh! drink the milk first.

[klutz]

Thanks for the info. It does have an electric start Norm, is the problem with the 3 bolts accessibility or are they just tight ?

[Norm]

Klutz, problem is they are countersunk and the Allan head is toop small for a stud of that size and unless you are very carefull they will round off and then it gets really ugly trying to get them out. I find I have to use an impact driver on them usually

[klutz]

Thanks Norm. Do you use a powered impact driver or will the ( much cheaper ) sort you hit with a hammer do it ?

[Norm]

Klutz I use the hammer type but I have to make up an Allan key to fit the 1/2 inch drive, nothing is ever simple

[klutz]

Thanks again for the help. You don't happen to know what size allen key fits the bolts do you ? It might be nice to get ahead of the game before putting the bike off the road for once.

[Norm]

Klutz not sure what size yours will be because the only ones I have here are from a 2006 model and by that stage they had gone metric on these and the Allan key for these is 5mm