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[Bertie the Bullet]

Hi all, seem to be getting a lot of false neutrals when selecting 3rd gear, dosn't matter if going up or down, could something be on its way out ?

[jefrs]

You don't say which bike model? Which gearbox? I have a little trouble finding neutral, and going down from third straight through second and into neutral /if/ the clutch cable is not adjusted just-so. Completely engaged when out and completely free when pulled in.

[PeteF]

I think Bertie is, err..., a Bullet

[Tim NZ]

The layshaft bushes are worn, the ends of the lay shaft WILL be scored to some degree, along with wear (rounding) of the projecting engagement dogs on the layshaft.


The Splined-bush on the near-side end of the layshaft can be replaced, the wear to the Kstart end of the lay shaft can be ground back, and a new bush made to suit.


But there is little to be done about extreme wear on the engagement dogs.


The quick fix is to simply replace the layshaft bushes and adopt the 'fingers crossed' approach and hope it does not come back???


The proper fix often involves the replacement of the layshaft, keeping in mind that most of the loading is at the Kstart end of the shaft; which is were most of the wear occurs...




All of which can be mitigated in the future by running the gear-box with oil instead of grease!


When running the 'box with oil it is prudent to have a small vent into the gear box. I drill a tiny wee hole in the Filler plug, done to prevent the possibility of oil being forced out past the mainshaft bearing oil slingers.

[jefrs]

Ah yes PeterF, which model of Bullet?

[Tim NZ]

If it is having 3rd gear issues, then it has have an Albion gearbox...

[Bertie the Bullet]

Sorry Gents, my bad, Bertie is a 2004 500 4 speed, right foot change albion gearbox.