Disassembly; Inspection - Triumph Rocket III Classic Service Manual

Disassembly
Note:
• All numbers given within brackets in the
procedure below refer directly to the
numbered items in the above diagram.
• For engines up to engine number 300895,
parts 8, 11 and 12 are no longer available.
Should these parts need to be replaced, use
parts 8 and 11 shown in the illustration for
output shaft - from engine number 300896
(see page 8-24).
• For engines from engine number
244280,
parts 14 (second gear) and 17 (dog ring), have
been changed. The second gear windows are
reduced from 6 to 4 windows and the second
gear dogs on the dog ring have increased from
6 to 8 dogs. These parts must be replaced as a
pair. See page 8-22 step 7.
• For engines from engine number 246088,
parts 9 (fourth gear), 6 (fifth gear) and 3 (first
gear), have been changed. The first gear
windows are reduced from 6 to 4 windows and
the first gear dogs on fifth gear have increased
from 6
to
8 dogs. These parts must be replaced
as a set. See page 8-23 step 14.
Make a note or mark the orientation of all parts prior to
removal.
1. Remove the ball bearing (1) and washer
<2>.
2. Remove first gear
(3)
and its needle roller bearing
(4).
3. Remove the first gear thrust washer (5).
4. Remove fifth gear (6), revealing a circlip
(7)
that
secures fourth and third gears.
5. Remove the circlip
(7).
6. Slide off the thrust washer (8) from in front of fourth
gear (9), then slide off fourth gear.
Z Slide off third gear (10), the splined thirdlfourth gear
bush (11) and the thrust washer
(12).
8. Remove the circlip (13) from in front of the splined
dog ring (14).
9. Slide off the splined dog ring (14).
10. Remove the circlip (15) from in front of second gear
(17).
11. Slide off the second gear thrust washer (16), then
second gear
(17)
and its bush (18).
12. Working now from the other end of the shaft,
remove the large nut (20), Belleville washer (21) and
flat washer (22).
13. Slide off the ball bearing (23), output gear (24) and
spacer (25).
Transmission
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.
Place the shaft (19) in a press with the threaded end of the
shaft facing the press ram. Support the centre bearing
(26) on press bars.
1. Press
2. Output shaft
3. Centre bearing
14. Press the shaft through the bearing.
Inspection
1. Examine all gears, bearings and bushes and thrust
washers for damage, distortion, chipped teeth and
wear beyond the service limits. Replace all suspect
components and always use new circlips to assemble
the shaft.
SelVice Manual - Rocket Ill/ Classic / Touring
8.21