6. ServiceManual-RocketIll

SelectorShaft,SelectorForksandDrum

RemovalNote:

• Priortoremoval,mark,ormakeanoteoftherelativepositionsofeachselectorforkintheselectordrum.

1. Removetheenginefromtheframeasdescribedonpage10.2.

2. Separatethelowercrankcasefromtheupperasdescribedonpage5.5.

3. Removetheoutputshaftfromthecrankcase.

4. Removethe'C'clipfromtheselectorshaft.

6.Pullingontheinsertedbolt,easetheselectorshaftoutfromthecrankcase,collectingeachselectorforkastheexitingshaftreleasesthem.

1.Selectorshaft

2.Bolt

3.Selectorforks

7. Removetheinputshaftasdescribedonpage

8.12.

8.

1. Selectorshaft

2. 'C'clip

5. InsertanM6bolt,handtightonly,intothethreadatthefrontendoftheselectorshaft.

1. Gearchangeactuatorarm

2. BoltNote:

   • Removalofthegearchangeshaftwilldetachthegearchangeactuatorarmastheshaftslidesout.Collecttheactuatorfrominsidethecrankcaseassoonasitisreleased.Inaddition,thedetentspringwillalsobecomedetachedfromthespringabutmentbolt.

ServiceManual-RocketIll

8.7

9. Slidethegearchangeshaftoutofthecrankcase,collectingthegearchangeactuatorarmanddetent springatthesametime.

1. Gearchangeshaft

2. Gearchangeactuator arm

3. Detentarm

10.Insertasoft-facedimplementthroughtheselector drumtopreventitfromturning,andthenundothescrewsecuring thedetentwheeltotheselectordrum.

1. Selectordrum

2. Detentwheel

11.Releasethesmallscrewsecuringtheselectordrum,bearingandkeeperplatetothecrankcase.

1.Selectordrumbearing

2. Screw

3. Keeperplate

12. Pull/pushtheselectordrumout andintodislodgethebearing,thenremovethe drumfromthecrankcase.

13. Toremovetheactuatorshaft,slideitinwardsandrecoveritfrominsidethecrankcase.

1. ActuatorshaftNote:

   • Itisnotnormallynecessarytoremovetheinnerselectordrumbearing,thoughitispossibletodosobydriftingfrombehind

itsrecessinthecrankcase.

14.Ifnecessary,removethespringabutmentbolt.

8. ServiceManual-RocketIll

Inspection

1. Inspectallspringsforover-extension(i.e.abnormalgapsbetweencoils). Replaceasnecessary.

2.Inspectallsealsfordamageanddistortion.Renewasnecessary.

Item	Standard		ServiceLimit
Selector fork	5.90 - mm	6.00	5.80mm
Selectorgroovewidth	6.05 - mm	6.15	6.30mm
Forktogrooveclearance	0.05 - mm	0.25	0.50mm

3.Checktheselectorforksandselectorgroovesforwearbeyondtheservicelimits.Renewcomponentsasnecessary.

thickness

Installation

1. Refittheactuatorshaft;ensuringitispushedfullyhomeinthecrankcase.

2. Locatetheselectordrumtothecrankcaseandengageitintheinnerbearing.

1. Innerbearing

2. Selectordrum

3. Fittheselectordrumouterbearing,bearingkeeperplateandretaintheplateusinganewscrew.Tighten thescrewto12Nm.

4. ApplyLoctite1305tothethreadsofthespringabutmentbolt(ifremoved).Fitandtightenitto23Nm.

5. Positionthedetentwheeltotheselectordrum,engagingthepinonthedrumwiththecorrespondingrecess intherearofthewheel.

1. Detentwheel

2. SelectorDrum

3.Pin

4.Recess

6. Fitanewscrewtothedetentwheel,preventthedrumfromturningusingasoft-facedtool,thentightenthescrewto12Nm.

7. Slidethedetentarmandspringontothegearchangeshaft,withthespringeyeendof thedetentarmenteringtheshaftfirst.

1. Detentarm

2. Springeye

3. Shaft

8. Positiontheassemblytothecrankcaseandpartengageitinitshole.

9. Locateandholdtheball-endofthegearchangeactuatorarmintheactuator.

ServiceManual-RocketIll

8.9

8. Feedthegearchangeshaftthroughthecrankcase,engagingitintheactuatorarmandalsoattachingthefreeendofthedetentarmspringoverthespringabutmentbolt.Ensurethatthegearchangereturnspringalsoengagesoverthespringabutment bolt.

1. Detentarmspring

2. Springabutmentbolt

3. Gearchangereturnspring

11. Fitanewbolttothegearchangeactuatorandlightenitto28Nm.

Note:

• Ifanew boltcannotbesourced,cleanthethreadsoftheoldboltandapplyaspotofthree-bond1305tothethreadsbeforefittingit.

Refittheinputshaftasdescribedonpage8.13.

Note:

• SelectorforksaremarkedA,BandC.Themarkinglettersalwaysfacetheclutchendoftheinputshaft.

Placethetransmissioninneutral.Thetransmissionisinneutralwhenthewheelofthedetentarmrestsin atoothonthedetentwheelthathasaV-shapedcut-out.

1.V-shapedcutout

2.Detentarm

14. Partiallyinserttheselector shaft intothecrankcase.

15. Positionandsupportthe selectorforksintheselectordrumasnotedormarkedpriortoremoval.

1. Selectorforks

2. Selectordrum

3. Selectorshaft

16. Feedtheselectorshaftthroughtheselectorforksandsecureiiwithanew'C'clip.

17. Assemblethecrankcasesasdescribedonpage

5.7.

16. Refittheengineasdescribedonpage10.5.