Final drive 11-1 11

Привод

Table of Contents

Взорванное Представление

Технические требования

Специальные Инструменты и Изоляторы

Цепь двигателя

Осмотр Провисания Цепи двигателя

Осмотр/Регулирование Регулировки колес

Осмотр Износа Цепи двигателя

Смазка Цепи двигателя

Удаление Цепи двигателя

Установка Цепи двигателя

Случай Цепи двигателя и Удаление Направляющей Цепи

Замена Цепи двигателя

Установка Цепи двигателя

Звездочка, Сцепление

Машинная Установка Звездочки Двигателя Удаления Звездочки

Заднее Удаление Звездочки

Задняя Установка Звездочки

Осмотр Износа звездочки

Задний Осмотр Деформации Звездочки

Удаление Подшипника сцепления

Установка Подшипника сцепления

Установка сцепления

Осмотр Подшипника сцепления и Смазка

11-2

11-4

11-5

11-6

11-6

11-6

11-6

11-6

11-6

11-6

11-7

11-7

11-8

11-9

11-9

11-9

11-10

11-10

11-10

11-10

11-11

11-11

11-11

11-11

11-2 FINAL DRIVE

Exploded View

FINAL DRIVE 11-3

Exploded View

No. 1 2 3 4	Fastener	Torque			Re­marks
		N-m	kgf-m	ft-lb
	Drive Chain Guide Bolts	11	1.1	95 in·lb
	Engine Sprocket Nuts	127	13	94	EO
	Rear Axle Nuts	108	11	80
	Rear Sprocket Nuts	33	3.4	24

CO: Apply chain oil. EO: Apply engine oil.

G: Apply grease.

L: Apply a non-permanent locking agent.

R: Replacement Parts

11-4 FINAL DRIVE

Specifications

Item	Standard	Service Limit
Drive Chain Chain Slack 20-link Length Standard Chain Make Type Link	35 ∼ 45 mm (1.4 ∼ 1.8 in.) 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) DAIDO KOGYO DID520VL2 108 links	––– 323 mm (12.7 in.) ––– ––– –––
Sprockets Rear Sprocket Warp	0.4 mm (0.016 in.) or less	0.5 mm (0.020 in.)

FINAL DRIVE 11-5

Special Tools and Sealants

Inside Circlip Pliers: 57001-143

Bearing Driver Set: 57001-1129

11-6 FINAL DRIVE

Drive Chain

Drive Chain Slack Inspection

• Refer to the Drive Chain Slack Inspection in the Periodic Maintenance chapter.

Wheel Alignment Inspection/Adjustment

• Refer to the Drive Chain Slack Inspection in the Periodic Maintenance chapter.

Drive Chain Wear Inspection

• Refer to the Drive Chain Wear Inspection in the Periodic Maintenance chapter.

Drive Chain Lubrication

• Refer to the Drive Chain Lubrication in the Periodic Main­ tenance chapter.

Drive Chain Removal

• Remove:

Rear Wheel (see Rear Wheel Removal in the

Wheels/Tires chapter)

Swingarm (see Swingarm Removal in the Suspension

chapter)

Engine Sprocket Cover

Drive Chain Guide

• Disengage the drive chain [A] from the engine sprocket [B], and take it off the chassis.

Drive Chain Installation

• Engage the drive chain with the engine sprocket.

• Install:

Swingarm (see Swingarm Installation in the Suspension

chapter)

Rear Wheel (see Rear Wheel Installation in the

Wheels/Tires chapter)

Engine Sprocket Cover

Drive Chain Guide

Torque-Drive Chain Guide Bolts: 11 N-m (1.1 kgf-m, 95 in-lb)

• Adjust the chain slack after installing the chain (see Drive Chain Slack Adjustment in the Periodic Maintenance chapter).

FINAL DRIVE 11-7 Drive Chain

Drive Chain Case and Chain Guide Removal

• Remove the dvive chain case mounting bolts [A], [B], and then removed the chain case [C].

• The chain guide [D] is installed together with the chain case with chain case mounting bolts [B].

NOTE

○Fit the chain case cover to the bracket groove on the swingarm at installing the chain case.

Drive Chain Replacement

NOTE

○Since the drive chain is installed through the swingarm, the chain cannot be removed other than by cutting it. Prepare the new link pin, link plate, O-ring, and tools for rejoining the chain.

• Remove:

Engine Sprocket Cover Drive Chain Guide

• Using the chain joint “ZJ” tool [A], cut the drive chain by removing the link pins [B]

Recommended Tool DID Chain Joint “ZJ”

Type: DID KASHIMARU

Make: DAIDO KOGYO

Pin Holder [A]

U type Holder [B]

Plate Holder [C]

Cutting and Rivetting Pin [D]

Adjusting Pin [E]

Aligning Mark [F]

11-8 FINAL DRIVE

Drive Chain

Drive Chain Installation

• Replace the link pin, link plate and grease seals.

• Apply grease to the link pins [A] and grease seals.

• Engage the drive chain on the engine and rear sprockets through the swingarm.

• Install the grease seals [B] on the link pins.

• Insert the link pins in the drive chain ends.

• Install:

Grease Seals [C] Link Plate [D]

○Install the link plate so that the mark [A] faces out.

• Using the chain joint “ZJ” tool [A], press in the link plate to the link pins after aligning the adjusting pin with the “A” mark on the U type holder.

• Using the chain joint “ZJ” tool [A], stake the link pin ends projecting from the plate after aligning the adjusting pin with the “B” mark on the U type holder.

• After staking, measure the outside diameter [A] of the link pin and link plates width [B].

Link Pin Outside Diameter Standard: 5.5 ~ 5.8 mm ( 0.217- 0.228 in.)

Link Plates Outside Width Standard: 17.9 ~ 18.1 mm ( 0.705 ~ 0.713 in.)

• If the reading exceeds the specified length, cut and rejoin the chain again.

• Check:

Movement of the Rollers

• Adjust the chain slack after installing the chain (See Drive Chain Slack Inspection in the Periodic Maintenance chap­ ter).

FINAL DRIVE 11-9

Sprocket, Coupling

Engine Sprocket Removal • Remove the bolts [A]. Pull the engine sprocket cover [B].

• 

  _{Flatten out the bended washer [A].}

• ^{Remove the engine sprocket nut [B] and washer.}

NOTE

○When loosening the engine sprocket nut, hold the rear brake on.

• Loosen the drive chain (see Drive Chain Slack Inspection in the Periodic Maintenance chapter).

• Pull the engine sprocket [A] off the output shaft along with the chain. Remove the engine sprocket.

Ц ffMMOl S

Engine Sprocket Installation

• Replace the sprocket washer with a new one.

• Install the engine sprocket so that the "OUTSIDE" mark [A] faces out.

• Be sure to fit the sprocket washer onto the output shaft splines.

• Apply oil to the threads of the output shaft [C] and the seating surface of the engine sprocket nut.

• After torquing the engine sprocket nut [A], bend the one side [B] of the washer over the nut.

NOTE

OTighten the nut while applying the rear brake.

Torque - Engine Sprocket Nut: 127 N-m(13.0 kgf-m, 94ft-lb)

• Install the engine sprocket cover.

• Adjust the drive chain slack after installing the sprocket (see Drive Chain Slack Inspection in the Periodic Mainte­nance chapter).

11-10 FINAL DRIVE

Sprocket, Coupling

Rear Sprocket Removal

• Remove the rear wheel (see Rear Wheel Removal in the Wheels/Tires chapter).

• Remove the rear sprocket nuts [A]. Remove the rear sprocket [B].

Rear Sprocket Installation

• Install the sprocket facing the tooth number marking [A] outward.

• Tighten the rear sprocket nuts.

Torque - Rear Sprocket Nuts: 33 N-m (3.4 kgf-m, 24 ft-lb)

• Install the rear wheel (see Rear Wheel Installation in the Wheels/Tires chapter).

• Adjust the drive chain slack after installing the sprocket (see Drive Chain Slack Inspection in the Periodic Mainte­nance chapter).

Sprocket Wear Inspection

• Visually inspect the engine and rear sprocket teeth for wear and damage.

• If the teeth are worn as illustrated, replace the sprocket with a new one, and inspect the drive chain wear (see Drive Chain Wear Inspection in the Periodic Maintenance chapter).

Worn Tooth (Engine Sprocket)

Worn Tooth (Rear Sprocket)

Direction of Rotation

NOTE

О If a sprocket requires replacement, the chain is proba­bly worn also. When replacing a sprocket, inspect the chain.

Rear Sprocket Warp Inspection

• Raise the rear wheel off the ground so that it will turn freely.

• Set a dial gauge [A] against the rear sprocket [B] near the teeth as shown, and rotate [C] the rear wheel to measure the sprocket runout (warp). The difference between the highest and lowest dial gauge readings is the amount of runout (warp).

• If the runout exceeds the service limit, replace the rear sprocket.

Rear Sprocket Warp Standard: less than 0.4 mm (0.016 in.)

Service Limit: 0.5 mm (0.020 in.)

FINAL DRIVE 11-11

Sprocket, Coupling

Coupling Bearing Removal • Remove:

Coupling [A]

Collar [B]

Sleeve [C]

Circlip [D]

• Remove the bearing by tapping from the hub side.

Special Tool - Bearing Driver Set: 57001-1129 [A]

Coupling Bearing Installation

• Replace the bearing with a new one.

• Press in the bearing until it is bottomed.

Special Tool - Bearing Driver Set: 57001-1129 [A]

• Pack the bearing with high temperature grease.

• ^{Replace the circlip with a new one.}

Coupling Installation

• Grease the following and install the coupling.

Coupling Internal Surface [A]

Ball Bearing [B]

Special Tool - Inside Circlip Pliers: 57001-143

Coupling Bearing Inspection and Lubrication

NOTE

○It is not necessary to remove the coupling bearing for inspection and lubrication. If the bearing is removed, it will need to be replaced with a new one.

11-12 FINAL DRIVE

Sprocket, Coupling

• 

  Spin [A] the bearing by hand to check its condition.

• If it is noisy, does not spin smoothly, or has any rough spots, it must be replaced.

• Examine the bearing seal [B] for tears or leakage.

• If the seal is torn or is leaking, replace the bearing. Pack the bearing with good quality bearing grease. Turn the bearing around by hand a few times to make sure the grease is distributed uniformly inside the bearing.