InstallingtheOutputShaft

6. Assemblethecrankcasesasdescribedonpage

5.9.

6. Refittheenginetotheframeasdescribedonpage10.5.

• ServiceManual-Rocket111

8.13

OutputShaft

1. Ballbearing

2. Thrustwasher

3. Firstgear

4. Needlerollerbearing

5. Thrustwasher

6. Fifthgear

7. Circlip

8. Thrustwasher

9. Fourthgear1o.Thirdgear

11. Splinedbush

12. Thrustwasher

13. Circlip

14. Dogring

15. Circllp

16. Thrust washer

17. Secondgear

18•secondgearbush19.Outputshaft

20. Nut

21. 'C'washer

22. Flatwasher

23. Ballbearing

24. Outputgear

25. Spacer

26. Ballbearing

14. ServiceManual-Rocket111

DisassemblyNote:

• Allnumbersgivenwithinbracketsintheprocedurebelow,referdirectlytothenumbereditemsintheabovediagram.

Makeanoteormarktheorientationofallpartspriortoremoval.

1. Removetheballbearing(1)andwasher(2).

2. Removefirstgear(3)anditsneedlerollerbearing(4).

3. Removethefirstgearthrustwasher(5).

4. Removefifthgear(6),revealingacirclip(7)thatsecuresfourthandthirdgears.

5. Removethecirclip(7).

6. Slideoffthethrustwasher(8)frominfrontoffourth gear(9),thenslideofffourth gear.

7. Slideoffthirdgear(10),thesplinedthird/fourthgearbush(11)andthethrustwasher(12).

8. Removethecirclip(13)frominfrontofthesplineddogring(14).

9. Slideoffthesplineddogring(14).

10. Removethecirclip(15)frominfrontofsecondgear(17).

11. Slideoffthesecond gearthrustwasher(16),

thensecond gear(17) anditsbush(18).

5. Workingnowfromtheotherendoftheshaft,removethelargenut(20)Bellvillewasher(21)andflatwasher(22).

6. Slideofftheballbearing(23),outputgear(24)

andspacer(25).

Neverwearlooseclothing,whichcouldbecometrappedinthepressandcausecrushinginjurytothehand,armsorotherpartsoftheanatomy.

5. Place theshaft(19)inapresswiththethreadedendoftheshaftfacingthepressram.Supportthecentrebearing(26)onpressbars.

1.Press

2. Outputshaft

3. Centrebearing

15.Presstheshaftthroughthebearing.

Inspection

1. Examineallgears,bearingsandbushesandthrustwashersfordamage,distortion,chippedteethandwearbeyondtheservicelimits.Replaceallsuspectcomponentsandalwaysusenewcirclipstoassembletheshaft.

_- ServiceManual-RocketIll

8.15

Assembly

Note:

• Lubricateeachgear,thrustbushwithcleanengineassembly.

washerandoil during

Note:

• Thecirclipsusedontheoutputshalthaveaflatsideandanangledside.Illustrationsthroughouttheassemblytextindicatewhichorientationofeachcirclipiscorrect.

1.Outputshaft

2. Bearing

3. Circlipgroove

4. Pressbars

2. Locatetheoutputshaft(19)tothebearing,withthethreadedendpointingthroughthebearing(i.e.awayfromthepress).

3. Presstheoutputshaftthroughthebearinguntiltheshoulderinthecentreoftheshaftcontactsthebearingface.

4. Fitthespacer(25)totheshaft,thenslideontheoutputgear(24).

5. Fitthebearing(24)totheshaftandretainwiththeflatwasher(22),Bellvillewasher(21)andnut(20).Tightenthenutto145Nm.

6. Workingfromtheotherendoftheshaft,slideonthesecondgearbush(18).

1.Placethecentreoutputshaftbearing (26)onpressbars,ensuringthatthepressbarssupporttheinnerraceofthebearingandthecirclipgrooveontheouterraceis nearestto thepressbars.