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Chapter 3: Disassembly and Reassembly
Note: The numbered parts in the following instructions refer to the annotations on the
exploded views.
3.1. Tools required
To assemble/disassemble the 4000 Mk2 wheel drive unit you will need a 3 mm allen key.
3.2. Disassembly
Remove the wheel drive from the wheel and release the clutch, then complete these steps:
Support plate and drive belt
1. Remove the front cover (1) by pulling it away from the back cover.
2. Remove the support plate:
•
unscrew and remove the 2 support plate screws (2)
•
lever the support plate (3) away from the back cover
3. Remove the drive belt:
•
lever the drive belt (4) up and over the machined pulley (13)
•
remove the drive belt from the drive ring (11)
Clutch eccentrics, knob and lever
4. Remove the 2 clutch rollers (5) from the clutch eccentrics. Note: the clutch rollers are
identical.
5. Remove the clutch lever:
•
unscrew and remove the clutch lever screw (6)
•
pull the clutch lever (7) off the back cover
6. Remove the clutch lever eccentric (8).
7. Remove the clutch ratchet knob:
•
unscrew and remove the ratchet knob screw (6)
•
pull the ratchet knob (9) off the back cover
8. Remove the clutch knob eccentric (8). Note: the clutch lever eccentric and clutch knob
eccentric are identical.
Bearing cage and drive ring
9. Remove the 3 parts of the bearing cage (10):
•
insert one end of the allen key into the joint between 2 parts of bearing cage (10),
then lever one part of the cage up so you can pull it out
10. Push all of the ball bearings together. The drive ring (11) will then be free to move.
11. Hold the drive unit horizontal, then lift off the drive ring (11).
8
4000 Mk2 Wheel Drive
4000 Mk2 Wheel Drive Service Manual 83158-1
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