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Transmission
Assembly
Note:
•
Lubricate each gear, thrust washer and bush
with clean engine oil during assembly.
Note:
•
The circlips used on the output shaft have a flat
side
and
an
angled
side.
Illustrations
throughout the assembly text indicate which
orientation of each circlip is correct.
Bushes with oil holes must always be MISALIGNED
with the corresponding oil holes in the output shaft.
Reduced oil pressure and gear lubrication may result
from alignment of the oil holes, which would cause
premature
wear
of
engine
and
transmission
components.
When using a press, always wear overalls, eye face and
hand protection. Objects such as bearings frequently
break-up under load and the debris caused during
break-up may cause damage and injury to unprotected
parts of the body.
Never wear loose clothing, which could become trapped
in the press and cause crushing injury to the hand, arms
or other parts of the anatomy.
1.
Place the centre output shaft bearing (25) on press
bars, ensuring that the press bars support the inner
race of the bearing and the circlip groove on the
outer race is nearest to the press bars.
3. Circlip groove
2.
Locate the output shaft (18) to the bearing, with the
threaded end pointing through the bearing (Le. away
from the press).
3.
Press the output shaft through the bearing until the
shoulder in the centre of the shaft contacts the
bearing face.
4.
Fit the spacer (24) to the shaft, then slide on the
output gear (23).
5.
Fit the bearing (22) to the shaft and retain with the
flat washer (21), Belleville washer (20)
6.
Apply ThreeBond 1305 to the nut (19). Fit the nut to
the output shaft and tighten
145 Nm.
Stake the nut
to the output shaft.
Z
Working from the other end of the shaft, slide on the
second gear bush
(17).
8.
Fit second gear (16) and the thrust washer (15).
9.
Fit a new circlip (14), orientating the circlip as shown
below.
ccbh
1.
10. Fit the splined dog ring
(13)
to the output shaft.
11. Retain the dog ring with a new circlip (12),
cobi
1.
Dog ring
2. Circlip
8.26
SelVice Manual- Rocket Ill/ Classic / Touring
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