Hitchcocks Forum

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

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

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

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.

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

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

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

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

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.

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