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[JTL]

Hi all... Bike: 2003 Bullet with 4 speed Albion gearbox. When removing the clutch I found the nyloc nut on the clutch mainshaft to be very easy to undo. It was like it had not been tightened at the correct torque, but as I had tightened it myself, I know it was done properly. As I'm working on the gearbox the gearbox inner cover is off too. The mainshaft LHT nut was tight as it should be (factory assembled). When the gearbox sprocket had to be undone, this nut was very loose as well. Only the tab washer had it stay. How can these two nuts get so loose? The reason for removing the entire chain case and opening up the gearbox is because I had some gear changing issues. Either I had to adjust the clutch cable a little loose causing big time problems changing the gears or it was too tight causing clutch slip during acceleration. The gears themselves change soft and smooth; no problems. My theory: the two nuts were loose because some slack had developed along the mainshft from behind the clutch assy all the way to the mainshaft nut. And the slack was caused by wear? Or? The inner oilthrower on the mainshft is stuck to the pinion just next to it like it was pressed on a little too much. The gearbox has 35.000 km on it. What to read from all this? Opinions are most welcome... regards Jacob

[Bullet Whisperer]

Hi Jacob, check the back of the clutch centre, it is likely the sharp ends of the gearbox mainshaft splines have chewed their way into it, causing play and a slack clutch centre nut. I have seen it on numerous occasions. Regards, Paul.

[JTL]

Hi Paul... I believe you are right about this. I can see some wear on the back of the clutch centre. Is this a common thing after 35K km or am I just being unlucky/lucky to experience this at this stage of wear. Our host stock part # 92826 as a cure for this. Is this the cure to go for? Do you have any suggestions for the loose gearbox sprocket? Maybe this was due to an undone mainshaft nut at the RH side? I certainly hope so because I have plenty to sort out in the gearbox. The layshaft bush in the kick start spindle is bust causing the end of the layshaft to be so worn I have to replace it. The splined bush at the other end is fine and so is the bush in the back of the gearbox. So 2 new bronze bushes and two new sealed bearing has to be fitted. The pressed on pinions on layshaft has to be taken of and re-fitted on a new layshaft. Well, a lot to do during winter lay up... regards Jacob

[Bullet Whisperer]

Hi Jacob, that looks like a part which could be useful to you, but the part description points out you will need to machine a little from the back of the clutch centre to restore alignment. As for a loose gearbox sprocket nut, I have seen plenty of them, even with the locking screw still in place, just tighten the nut and all will probably be ok. Make sure any bushes you replace in the gearbox are not too tight once fitted - we had a new layshft bush cause a gearbox lockup at 100 mph at Pembrey about 10 years ago - another reason for my using 20/50 oil in those gearboxes! Good luck and take care with it. Regards, Paul.

[JTL]

Thanks for advice Paul. I will be very careful, especially with your story about the gearbox lockup in mind. I have all winter to get this right, so patience is still my companion... regards Jacob