Hitchcocks Forum

Hi I recently rebuilt my 1990 500 bullet gearbox with new bearings and seals ( due to leaks)
The clutch was stripped and inspected, reassembled , on test driving I found I was getting clutch drag
Causing it difficult to shift especially down ( high to low) on pulling the lever you could feel the gears had not disengaged . I fitted a new clutch end plate and finger with bearing from our host but still the problem is there.
I have set the cables / adjuster as per instructions here ( release lock nut - adjust screw to feel tension - back off half turn, adjust handle bar to 5mm play - still same ) have tried taking more slack from cable but still seems to drag. I have inspected to plates to make sure the dishes are round the right way !!!!
Any ideas ??

Carry out all adjustments with a cold gearbox.

What works for me.

Remove all slack from cable and actuator in box.

Fit cork plates with three heavy and three standard springs.

Run ATF in the primary case, 20-50 oil seems to increase drag..

Fit the case strengthener to stop the outer case from flexing as much when pulling clutch in..

You have to gain as much lift as possible from a marginal design let down by poor indian metallurgy and construction..

Much the same as Gwilly
Still on the bonded? plates I fitted 20 yeras ago replacing the original carp items, much later came the 3 light & 3 heavy springs, then more recently the outer cover strengthener and that did make a noticeable difference, finally following the advice here (and other places) changed the lube from 20w fork oil to ATF, no noticeable difference.
Can't remember how the operating lever is set, probably at about 90 degrees to the cable when fully disengaged. When the cable is reconnected after lubing it is adjusted with just a bit of slack.
The unpleasant gear shifting was sorted by following advice given by Allan H some 20 odd years ago when he, Dan

Seem to have lost the end of my tale
to continue - The unpleasant gear shifting was sorted by following advice given by Allan H some 20 odd years ago when he, Dan and I think AN Other used to be at Kempton. Invaluable advice freely given at that time to a guy coming back to bikes after meny years and of all things coming back with a badly abused 1992 Bullet 500!

Thanks guys, I'm currently running the gearbox on 80/90 , so wondering if a change to ATF might help ? Does anyone know how much oil it takes as to my memory it has no level plug?

Mikey: Don`t put automatic transmission fluid in the gearbox; it goes in the primary chain case where the clutch is mounted. Use ATF for Fords, if available.

Hmmm cheers (ref oil )
Was wondering if a thinner oil might help ?

No clutch drag is the alpha and omega of the problem. With Gwilly's recipe you'll have a gearbox that changes and selects like a goodun.

I cured my clutch drag by making a stiffener for the gearbox outer 9before the H one was available). HERE
Simon's right, thinner oil in the gearbox is not the answer (though ATF would work OK in the box)