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Tech. Advice: Series 'B' / 'C' 500cc/1000cc Bikes
Burman 4th Gear Selector Meltdown
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<blockquote data-quote="Matty" data-source="post: 110931" data-attributes="member: 1339"><p>Hi</p><p>In 2011/2012 there were many pages on the forum about this problem.</p><p>I think the thread number is php?4089.</p><p>My comet gearbox was mechanically OK but because I was about to fix some leaks and change bearings etc. I wanted to optimise the clearances etc for the rebuild and a few of us (tatty 500, Vic Youle, ClevTrev, self etc) embarked on a long series of correspondence on the subject of Comet Burman gearboxes.</p><p>I will try to find a summery which is in my computer –which may be on the forum anyway and will attach it to this email.</p><p>There are other bits and pieces of text on this subject which may answer other questions.</p><p>I have now done many thousands of miles with my rebuilt box and other than an exercise to fix a leak of grease from round the gearlever it has been fine and ridden from Essex to the Isle of Man at least seven times since the rebuild.</p><p>I hope the others involved in the investigation have also had similar success.</p><p>As for end play, I just tried to get around 4mm of overlap on the top gear dogs with all the tolerances pushed one way - that way (with a small spacer behind the output gear) it does not want to jump out of top gear.</p><p>The spacer in theory will put the sprocket out of line a bit but it does not seem to have caused any problems.</p><p>MAKE SURE THE GEAR INDICATOR IS NOT TOUCHING THE LEVER WHEN IN TOP.</p><p>Also I seem to remember I had to make sure the output gear cleared the bronze selector by around 1mm with the spacer in and is of small enough diameter to fit inside the casing – it turned out to be quite a thin ring at its circumference probably only a couple of mm I seem to remember.</p><p>Best of luck.</p><p>Matty</p></blockquote><p></p>
[QUOTE="Matty, post: 110931, member: 1339"] Hi In 2011/2012 there were many pages on the forum about this problem. I think the thread number is php?4089. My comet gearbox was mechanically OK but because I was about to fix some leaks and change bearings etc. I wanted to optimise the clearances etc for the rebuild and a few of us (tatty 500, Vic Youle, ClevTrev, self etc) embarked on a long series of correspondence on the subject of Comet Burman gearboxes. I will try to find a summery which is in my computer –which may be on the forum anyway and will attach it to this email. There are other bits and pieces of text on this subject which may answer other questions. I have now done many thousands of miles with my rebuilt box and other than an exercise to fix a leak of grease from round the gearlever it has been fine and ridden from Essex to the Isle of Man at least seven times since the rebuild. I hope the others involved in the investigation have also had similar success. As for end play, I just tried to get around 4mm of overlap on the top gear dogs with all the tolerances pushed one way - that way (with a small spacer behind the output gear) it does not want to jump out of top gear. The spacer in theory will put the sprocket out of line a bit but it does not seem to have caused any problems. MAKE SURE THE GEAR INDICATOR IS NOT TOUCHING THE LEVER WHEN IN TOP. Also I seem to remember I had to make sure the output gear cleared the bronze selector by around 1mm with the spacer in and is of small enough diameter to fit inside the casing – it turned out to be quite a thin ring at its circumference probably only a couple of mm I seem to remember. Best of luck. Matty [/QUOTE]
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Tech. Advice: Series 'B' / 'C' 500cc/1000cc Bikes
Burman 4th Gear Selector Meltdown
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