Output Shaft Assembly - Triumph T595 DAYTONA Service Manual

Assembly
NOTE:
• Lubricate each gear and bush with clean engine
oil during assembly.
Examine all gears, bearings and sleeves for
damage, chipped teeth and wear beyond the
service limits. Replace all suspect components
and always use new circlips to assemble the
shaft
1. Working from the output sprocket end of the shaft, fit
a new bearing (24) to the shaft using a press and
press bars.
2. Fit the retaining ring (23) to the shaft. Lubricate and
fit a new oil seal (22) and fit the sprocket sleeve (25).
3. Transfer the shaft to the vice and secure between
soft jaws. Fit the sprocket (21), locktab (20) and nut
(19). Tighten the nut to 132 Nm. Close the lock tab.
4. Withdraw the shaft from the vice and continue to
assemble from the opposite end to the output
sprocket.
5. Locate the second gear (17) to the shaft with the
large step side facing away from the output
sprocket end. Fit the thrust washer (16) and retain
with a new circlip (15).
6. Fit sixth gear (14) with the selector fork groove
facing away from the output sprocket end. Ensure
that the oil hole in the gear aligns with the double oil
hole in the output shaft.
1. Double Oil Hole
2. Gear Oil Hole
CAUTION: Incorrect alignment of the oil
• holes will result in severe damage to the
gears and gear selectors.
7.
Fit a new circlip (13) to retain sixth gear.
8. Fit the thrust washer (12) to the rear of fourth gear
and fit the splined sleeve (11) for fourth gear.
Ensure correct alignment of the oil hole in the shaft
with the oil hole in the sleeve. Fit fourth gear (10) to
the shaft with the large step side facing away from
the output sprocket.
9. Fit the splined bush (9) for third gear taking care to
align the oil hole in
hole in the bush. Fit third gear (8) with the larger
step side facing the output sprocket.
10. Fit the thrust washer (7) and retain with a new circlip
(6).
11. Fit the fifth gear (5) to the shaft with the circular dog
teeth facing away from the output sprocket.
12. Fit first gear (4) to the shaft as marked during
disassembly.
13. Finally fit the thrust washer (3), needle roller bearing
(2) and bearing cap (1) to the end of the shaft.
7.21
TRANSMISSION 7
the shaft with the corresponding
,