Forum

[Paul M H]

I need too remove the primary drive & stater on my 65 work bullet as I'm going to remove the electric starter & get the inner primary kit from Hitchcocks to replace mine as well as changing to a 18 tooth gear box sprocket at same time. What I need to know is what size sockets to I need for the clutch basket removal & alternator rotor & gear box sprocket and any other bits so I've got it all to hand before I start. I think I've got most pullers that will work I need.

[Nettshubby]

You need a 19mm socket for the clutch nut. I'm Not sure about the alt rotor, but it's either the same size or something like 21mm, spark plug size. The gearbox sprocket on the Sixty5 is 50mm, yes, 50! And don't buy a socket, unless you get a deep type, because the final drive shaft pokes through the square in the socket and leaves hardly any room for the square on the ratchet bar. (Don't ask me how I know!) Best get a tube/ box spanner, like H's sell to give you the length you need.

[Norm]

Paul one of the problems can be getting the countersunk screws undone that hold the inner primary on, I usually need to use an impact driver on them if they have not been removed from factory

[Nettshubby]

Yes Norm, one of mine was especialy stubborn, had to give it a persuaisive "tap" with a drift and hammer, to save chewing the hex up altogether. Replaced all 3 with new screws and loctite!

[mauri]

this is the type of tool you’l need for the alternator nut, 26mm

it is not used in the correct way(to long) in the picture, it needs to touch the bottom(red circle) of the sprocket teeth and not the top of the teeth.

the end needs and egde to and not a straight cut as seen.







found this on a blog, and is a great 3in1 tool







it a clutch holder, clutch puller, front sprocket puller.

clutch center nut is 18mm.

[mauri]

forgot this.



primary cover nut 18mm

clutch cap 12mm

stator 11mm

rear primary cover 13mm



behind clutch basket is a 10mm nut

[Norm]

Netshubby, why did you use Loctite, going to make it really hard to get them out next time.When I have been caught with Loctited ones I have had to get in there with a grinder and cut a slot in the head and the heat generated by cutting the slot has been enough to break the Loctite grip. Only reason they did them so tight was because of the forces applied when using the starter but if you have no starter they won't come loose so they don't need to be that tight. I have never seen them come loose but I guess the factory wanted to be sure

[Nettshubby]

Belt & braces Norm. As you can't put any sort of locking washer under the head I didn't want any chance of them coming loose. I've found enough loose bolts and nuts on the bike already, the latest being the two disc calliper mounting bolts! Luckily the mudguard stay covers them and stopped them dropping out altogether. I agree that heat is the normal way to destroy a loctite bond, but I'm hoping I won't have to go in there again! ( famous last words ).

[Nettshubby]

Mauri, I measured the nut I took off the clutch and it was 19mm across flats. It's a 12 mm fine thread, according to H's parts book.

[Nettshubby]

BTW Norm, I do still have a starter, and it's working fine, though I only use it in emergencies, stalls at lights and such. Though with the new Motobat battery and the earth nut replaced with a Nyloc, to stop it coming undone again, it will start the bike even in winter cold.