Forum

[TexasChris]

Hi Folks,

I've got a Bullet 500, 4 speed that has been sat for a few years. following a bit of an external make over, I just want to ensure the internals and lubricants are good to go. So engine and primary oil can be changed, and I've read that gearboxes can be "topped up" with oil that mixes with existing grease.

But is there a way to check the amount grease in there? Is it worth mixing in a bit of extra EP00 with the "top up" oil just to be sure? Any consequences of over greasing?

It rode fine when I bought it almost a year ago, and its a real low mileage bike so there shouldn't be any issues, I'm just trying to be appropriately thorough with maintenance stuff before I start riding it.

Thanks,
Chris

[Presto]

The 4 speed gear box is an under-stressed gearbox and lubrication is not anything to worry over.

Grease is used not so much for any preferred lubrication qualities but because it helps prevents oil leakage through the unsealed bearings factory fitted.

Engine oil [20w/40] or gear oil [80-90] are also suitable, but if unsealed bearings are fitted then expect oil leaks.

Grease does not need to be replaced unless the gear box is stripped and assembled.

Topping up with engine oil is recommended. A level plug is situated on the rear case of the box about 3/4 the way up the box.

The ratio of oil to grease is really of no consequence - other than if the oil is diluted to an excessive degree oil leaks may occur, but lubrication will not be adversely affected.

[TexasChris]

Noted!
Thank you, straightforward answer!

[vince]

Hi, I replenish the gearbox with grease using a bicycle pump, filled through the level plug with the top plug out to allow the air out. Vince

[Clement]

I have a cast iron 2003 Bullet with okay bearings in the gearbox. I flushed the grease out by topping up with 100 - 200 mls of kerosine; took bike for very short 2 minute ride; drained whatever came out; re-applied kerosine up to 6 times with intermittent very short rides which dislodged all the grease; flushed box clean and filled with Castrol 20W50 oil. Grease came out in fat black blops. Worked for me.

Clement

[curryinahurry]

Just done a 500cc 4 speed , mid 90's , i used self levelling grease (NLGI 00) from memory as i bought a 20 kilo pail years ago , filled with a big syringe through the level hole , at the rear of the gearbox.

[PeteF]

You will need to check the level when it's good and hot otherwise it doesn't flow.
It should not need replacing until very high milage.
Just top up with 20/50

[Duke of Wybourne.]

I have a cast iron 2003 Bullet with okay bearings in the gearbox. I flushed the grease out by topping up with 100 - 200 mls of kerosine; took bike for very short 2 minute ride; drained whatever came out; re-applied kerosine up to 6 times with intermittent very short rides which dislodged all the grease; flushed box clean and filled with Castrol 20W50 oil. Grease came out in fat black blops. Worked for me.

Clement

Possibly dangerous, but I used to flush mine out with boiling oil heated in an old metal Castrol jug on a camping stove. Managed to have a peek inside with an endoscope and everything looked nice and clean.

[Wheaters]

To help remove old grease... pressurise casing via an airbed connector in fill plug aperture.