Re-Assembling The Rear Suspension - Whyte G-160 Works Supplementary Service Manual

6.3: RE-ASSEMBLING THE REAR SUSPENSION.

6.3.1: Re-assemble the Whyte G-160
Tools Required:
Reference figures 18 & 19. The re-assembly of the rear suspension is essentially the re-
verse of the dis-assembly procedures 6.1.1.1 & 6.1.1.2.
6.3.1.1: To re-assemble the link (20), shock extender (7) & swinging arm parts
(17 & 18) onto the main frame (16).
Starting with the Seat-stays (17 & 18) and the H-link (20), reference figure 18, first check
that the shield washers are in place in the H-link (see items 2 in figure 13) and apply either
SKF LGAF 3E or Castrol Optimol T anti-fret paste to the contacting faces between the shield
washers and Seat-stays (17 & 18). Then ensure that the shield washer in the H-Link (20)
is not pushed out, as you place the right seat-stay (17) inside it. Then pass an M8 x 20
long Socket-head Capscrew (15) through that seat-stay (17), the adjacent shield washer,
and the KP5AX bearing in the H-link (20). Screw an M8 Flanged Nut (9) onto the end of
that M8 screw (15) up to the KP5AX bearing. Using a 10mm Socket and the 5mm AF Allen
Key, torque tighten the M8 Flanged Nut (9) and the M8 screw (15) to the recommended
torque settings (refer to the Tightening torque settings in Section 8.0). Repeat that task to
assemble the left seat-stay (18) to the H-link (20), also ensuring that the other shield
washer in the H-Link is not pushed out.
CAUTION: The 5mm A/F hexagon socket in the M8 screw (15) is only intend-
ed for holding the screw to prevent rotation. So the tightening torque MUST
ONLY be applied to the M8 Flanged Nut (9).
Next, to assemble the shock extender (7) and the H-link (20), reference figure 18, first
check that the shield washers are in place in the H-link (see items 2 in figure 13) and apply
either SKF LGAF 3E or Castrol Optimol T anti-fret paste to the contacting faces between the
shield washers and shock extender (7). Then ensure that the shield washers in the H-Link
(20) are not pushed out, as you place the shock extender (7) inside them. Then pass an
M8 x 20 long Socket-head Capscrew (15) through one arm of the shock extender (7), the
adjacent shield washer, and the KP5AX bearing in the H-link (20). Screw an M8 Flanged
Nut (9) onto the end of that M8 screw (15) up to the KP5AX bearing. Using a 10mm Sock-
et and the 5mm AF Allen Key, torque tighten the M8 Flanged Nut (9) and the M8 screw
(15) to the recommended torque settings (refer to the Tightening torque settings in Sec-
tion 8.0). Repeat that task to assemble the other arm of the shock extender (7) to the H-
link (20), also ensuring that the other shield washer in the H-Link is not pushed out.
Page 26
WHYTE Service Manual
4mm AF Allen Keys (2 off, 1 fitted to a 5Nm to 25Nm Torque Wrench)
5mm AF Allen Key - ball ended (1 off)
6mm AF Allen Key (1 off)
8mm AF Allen Key (1 off,
15mm Open-ended, or adjustable spanner
T-25 Torx® Keys (2 off, 1 fitted to a 5Nm to 25Nm Torque Wrench)
Medium sized flat-bladed screwdriver (1 off)
10mm AF Socket (2 off, 1 fitted to a 5Nm to 25Nm Torque Wrench)
10mm open ended spanner
fitted to a 5Nm to 25Nm Torque Wrench)
2016 Edition 1