Changing gears on bullet 500 Cast iron

[deepikins]

Hi all,

I have this weird problem all of a sudden. My babe has done 25K kms and has been properly run. Suddenly after the last Servicing ( nothing major was done), there is a terrible sound when i change my gears. Also, the smoothness that i changed the gears earlier, is missing.
Any reasons this could pop up suddenly? also, my mechanic suggests changing the clutch plate to 5 speed. is this good?
Please let me know.

[iron]

while changing do u completely disengage the clutch and then shift or do u shift at half clutch?

[masterblader]

Never heard of a 5 speed clutch? Please explain
If the clutch is suspect there are several checks needed.
1. cable correctly adjusted
2. friction plates within working tolerances
3. plain plates are true and not distorted
4. clutch spring length within working tolerances
5. If pushrod operated ensure correctly seated and bush in good condition
Some motors have 2 different types of friction and plain plates and if not assembled as per factory a clean gear change will not be acheived.
Good luck bud

[nitro.1000bhp]

I had the problem with mine a few times, tighten the clutch cable ( thats what my mechanic said he did). the problem went away immeditly.

[iron]

Originally Posted by masterblader

Never heard of a 5 speed clutch? Please explain

he probably means 5 plate clutch.
post 2003-04 all bikes were equiped with the 5 plate clutch.
correct me if i am wrong.
AFAIK 5 plate clutch were factory provided for the CI500
it was the CI350 that came wit 4plate clutch this was pre-2004.

[masterblader]

Hi Deep Try and adjust the clutch manual setting. Slacken off adjuster at handlebar end, undo the inspection plug on the clutch cover you will see an aduster screw with a locknut on the pressure plate. Undo the locknut with a screwdriver turn the adjuster until you feel contact at the other end now back off just a smidge and tighten locknut.
Take up the slack using the adjuster on the handlebar leaving approx 1/16" freeplay.
Pretty sure you will get a result. Good luck mate

[deepikins]

Originally Posted by iron

while changing do u completely disengage the clutch and then shift or do u shift at half clutch?

I depress the clutch completely always. never at half clutch.

Originally Posted by masterblader

Never heard of a 5 speed clutch? Please explain
If the clutch is suspect there are several checks needed.
1. cable correctly adjusted
2. friction plates within working tolerances
3. plain plates are true and not distorted
4. clutch spring length within working tolerances
5. If pushrod operated ensure correctly seated and bush in good condition
Some motors have 2 different types of friction and plain plates and if not assembled as per factory a clean gear change will not be acheived.
Good luck bud

Thanks, will get the checks done over the weekend.

Originally Posted by nitro.1000bhp

I had the problem with mine a few times, tighten the clutch cable ( thats what my mechanic said he did). the problem went away immeditly.

Did this the first time itself. does not solve the issue.

Originally Posted by iron

he probably means 5 plate clutch.- You are right.
post 2003-04 all bikes were equiped with the 5 plate clutch.
correct me if i am wrong. i have a 2004 model and it came with a 4 plate clutch. this was a august model.
AFAIK 5 plate clutch were factory provided for the CI500
it was the CI350 that came wit 4plate clutch this was pre-2004.

Mine is a 500 CI

Originally Posted by masterblader

Hi Deep Try and adjust the clutch manual setting. Slacken off adjuster at handlebar end, undo the inspection plug on the clutch cover you will see an aduster screw with a locknut on the pressure plate. Undo the locknut with a screwdriver turn the adjuster until you feel contact at the other end now back off just a smidge and tighten locknut.
Take up the slack using the adjuster on the handlebar leaving approx 1/16" freeplay.
Pretty sure you will get a result. Good luck mate

cool, thanks a ton, will try this over the weekend first and then let you guys know.

Thanks guys for the reply. will let you know of the results.