Forum

[John R]

Thanks all. As to the movement of the kickstarter, what concerns me is that mine didn't do that before as far as i can see. I have recently replaced the return spring, and as Pete F says if it was broken the K/S would not return at all. I am inclined to suspect the bush has failed. Now i am in new territory here; is it a case of removing the outer and inner covers to access the end of the layshaft, or will I need to do further disassembly from the other side? I hace looked briefly at the tech notes but they don't mean much without the opened up gearbox in front of me.

[Chris [Stockport]]

My Year 2000 Bullet 500 did this movement a lot, for the first couple of years and then did it less and less. I didn't change or repair anything. The only actual problem I feel we should avoid, is looking down at it to see what's happening or you might bump into the back of a car. Don't ask. My Year 2007 Bullet 500 hardly ever does it. atb Chris

[PeteF]

John,
There's a tech note on here about replacing the pawl. That guides you through most of what you need to do. The bush should push out once you have the kickstart shaft out. It's not difficult, but note that the nut on the end of the mainshaft is LHT. If you replace the pawl while you're in there, just make sure it "parks" properly. I didn't and had to strip it again. If I remember I had to grind the new pawl a little.
As it's a 350, it's well worth thinking of a close ratio conversion as well. It gets rid of the big jump from 3rd to 4th and makes the bike a lot better.

[Norm]

The bush will not just push out, that is just an urban myth,packing with grease to get them out is another part of this myth, every one I have replaced I have had to bore out in the lathe and usually after fitting the new bush it has shrunk and will not fit the shaft and requires a skim taken out of the bush in the lathe

[PeteF]

I've only done this once Norm but I had no problems.

[John R]

Man versus myth! Thanks for this, the kickstart pawl notes make it much clearer than the gearbox over haul notes. So when I come to do this, could I replace the pawl, replace the dodgy bush and possibly fit the close-ratio gear cluster without disturbing the clutch? It won't be any time soon and will be an outdoor job; hope I don't need a lathe!

[PeteF]

John,
It depends on how hard it is to get the pinion off the mainshaft.
Mine came off OK with a bit of heat.
Here’s a write up of my experiences.

[John R]

Thanks again, Pete, this will be very helpful. The Humberside site always seems well supported - with the looming expiry of my Guernsey housing license, perhaps it's a part of Britain I should consider!

[Tim NZ]

Norm:
A lot easier to tap a thread into the bush and then simply screw in a bolt.
The K start flicks back due to friction between the layshaft and bush. Convert to oil filled Gbox should fix, if it does not, then the gear box is also likely to be jumping out of third gear. Then new layshaft and bushes are required.
Tim

[Norm]

Tim for me a lot easier to stick it in the lathe that mess about cutting a tread in them. lol