Triumph Daytona 675 User Manual page 25

A9618066 - 1st gear pair & housing
1. Remove the existing
assembly from the engine following the
procedures detailed in section 7 of the
Daytona 675 service manual.
2. Remove the output shaft bearing and
plain thrust washer from the existing
output shaft assembly.
3. Replace the existing 1st gear with the
race kit 1st gear (2) supplied. Ensure
the orientation of the race kit 1st gear
is the same as the standard 1st gear.
Lubricate the 1st gear and 1st gear
bush with clean engine oil during
assembly.
4. Re-assemble the plain thrust washer
and output shaft bearing onto the
output shaft.
5. Remove the existing selector drum
assembly from the engine following the
procedures detailed in section 7 of the
Daytona 675 service manual.
6. Remove the existing detent wheel and
fixing from the selector drum assembly.
Note how the detent wheel is timed
relative to the selector drum by way of
a dowel.
7. Assemble the race kit detent wheel (7)
to the selector
ensuring it is timed to the drum in the
same way as the original detent wheel.
8. Fit the M6 Torx head screw (8) to the
selector drum assembly and tighten to
a torque value of 12 Nm. Ensure the
detent wheel (7) is fully inserted into
the bearing, up to its shoulder.
© Triumph Designs Ltd 2008.
output shaft
drum assembly,
Page 25 of 33
9. Remove the existing input shaft from
the engine following the procedures
detailed in section 7 of the Daytona 675
service manual.
10. Remove all gears, circlips, bushes and
washers from the original input shaft,
taking care to note the orientation of
components in
recommendations in section 7 of the
Daytona 675 service manual. Discard
the two small circlips and splined
washer, which sits adjacent to the 5th
input gear on the shaft.
11. Re-assemble all gears, bushes and
washers from the original input shaft
onto the race kit input shaft assembly
following the procedures detailed in
section 7 of the Daytona 675 service
manual. Ensure the new circlips (6) and
splined washer (9) from the race kit are
used.
NOTE
• The race kit splined washer (9)
replaces the
washer adjacent to the 5th input
gear. The standard splined washer
in this location cannot be used in
conjunction with the race kit and
must be discarded.
12. Re-assemble the input shaft assembly
into the upper crankcase in line with the
recommendations in section 7 of the
Daytona 675 service manual.
13. Fit the new bearing retainer plate (4)
and secure with the new fixings (5)
provided. Tighten the fixings to a
torque value of 12 Nm.
line with the
standard splined