Forum

[Toddy]

I was having gear shift problems on my 1996 Bullet. I noticed that the gear operater pin bush 111085 had worked loose and fallen out. Is this adjustable or does it screw tight into the gear box casing, there is no mention of it in the manual.

[Gwilly]

Hi Toddy, Sounds like a real sod to sort out.. I know that the pin,bush and the operator are the only parts you cannot strip from the casing without splitting the gear case from the engine..The bush is screwed in tight and possibly staked, so is not adjustable... Like i said a real sod with so much work to make such a simple repair..

Not tried it myself but have heard it may be possible to release the stud nuts (gearbox to engine) and wangle the engine forward on supports to give enough clearance....

Failing that drop the lot out and check over the motor whilst repainting the frame.. Not exactly planned maintenance but gives you something to do over the winter.. gwilly

[Toddy]

Gwilly

Thanks for the reply.
The pin is still in place, its the bush that worked loose and fell out, I was lucky to find it under the bike after an attempted ride (in fact I was not sure it was from the bike as Id never noticed it before being in such an awkward place). Question is is it possible to just screw it back with the pin in place or as you suggested a big job ? If so what is the alignment procedure.

Regarding winter, Im in Papua New Guinea so we dont have too much of that

[Gwilly]

Toddy if you can devise a method of holding and turning the bush into place in such a confined space, then i take my hat off to you..

Maybe a drop of loctite stud lock may give sufficient security.. My fear is that to simply realign the pin if not central may require removal of the inner gear case to allow manipulation of the pin and bell crank (gear operator). But hey I'm being pessimistic, sorry. Just go for it and maybe lady luck will smile on you... Best wishes gwilly..

[Mark M]

Toddy, if you can get the bush back into position all should be well, there isn't really anywhere for the pin and selector fork to go and the sliding forks and gears are retained between the shafts so no problems there. If you do have to remove the gearbox it is possible to get it out without removing the engine (I've done it,) but you have to strip so much away, including the rear engine/gearbox plates and stand, that it's barely worth the effort saved.
REgards, Mark

[Toddy]

Im afraid lady luck was not on my side , turns out the pin came out and the step is worn to buggery. I guess caused by me crunching into gears after the bush fell out. Not sure if that was cause or effect.

I do have another bullet for spares, question is-

1. Is it easier to split the box to fix the pin issue or swap the box complete.
2. Working bike is RH shift spare bike is the other side, does that pose a problem.

Thanks again for you advice.

[Toddy]

Forgot to mention, Id rather keep to spare bike together, its not like I have the gearbox out already.

[Norm]

Toddy, looks like you will have to pull the motor and box out to see what can be done, if some repair can be done, possibly JB Weld the pin into place, just make sure it is in the right spot, probably pay to get a new pin. Will not matter if you can't get the pin out in the future, the case is pretty shot now anyway. You could pick up another case from ebay but I would have a crack at it with the JB Weld. Not sure what sort of facilities you have up there and I think there is only half a dozen Enfields in PNG and you have 2 of them

[Toddy]

Norm

Thanks for the reply. The thread in the case is good. Im not sure whats involved in replacing with a new pin when the box is split.
Are you saying that the stuff up may have lead to internal damage within the case.

As far as I know there are two other Bullets here (off the road at the moment), someone else is bringing a couple more in direct from India. There were others but they ended up in Australia.

Regarding the LH/RH shift issue, are the boxes easily interchangable. Before I pull everything apart would like to know the options.

From an engineering design point of view the bush may have been better screwed in fronm the inside of the case, that way it could not work loose and fall out ?

[Norm]

Toddy,
What part of the housing is damaged, where the pin locates in the rear of the housing? I doubt that there would be too many problems caused by it unless you were really crashing it through the gears and then things can get damaged. Fitting the left shift box is fairly straight forward, you have to use the right shift end cover and the outer cover but because the rerar of the cases are different to take the crossover shaft, in the end to get the second bike back together you would have to swap the boxes again or convert the second bike to right shift. No big deal but a lot of work and you will end up with 2 bikes in bits and parts scattered everywhere. Should only take you a couple of hours to get the motor and box out and then you can split the box off and asses the damage. This is providing you have a tool to get the clutch hub off and the rotor sometines can need a puller. Apart from that it is fairly straight forward