8.16 ServiceManual-RocketIll

7. Fitsecondgear(17)andthrustwasher(16).

8. Fitanewcirclip(15),orientatingthecirclipasshownbelow.

"""

1. Secondgear

2. Circlip

9. Fitthesplineddogring(14)totheshaft.

10. Retainthedogringwithanewcirclip(13),orientatingthecirclipasshownbelow.

1. Dogring

2. Clrclip

11. Fitthethrustwasher(12)andsplined bush(11).

12. Slidethirdandfourthgears(10and9)ontothesplinedbush.

13. Fitthethrustwasher(8),thenanewcirclip(7),orientatingthecirclipasshownbelow.

1. Third/fourthgear

2. Clrcllp

14. Fitfifthgear(6)totheshalt,followedbythethrustwasher(5).

15. Tocompleteassemblyoftheoutputshalt,fittheneedlerollerbearing(4),firstgear(3),thrustwasher(2)andbearing(1).

_- ServiceManual-RocketIll

8.17

Transmiss1^.0ⁿ

InputShaft

1. Torx_screinerplate

2. Bearingr_e

   1. Ballbearm

4Retainingring5·^Inputshaft

6. Thrustwasher

7. Bellevillewa^shers

8 Fifthgear₉.Fifthgearbush1O.Thrustwa^sher

l1Circlip r

₁₂._{.Third/fourth}gea1a.Circllp

14.SeCondgear

lS.Circlip

8.18

ServiceManual-Rocket111

Disassembly

1. Removethecirclip(15)frominfrontofsecondgear(14).

2. Removesecondgear(14).

3. Removethecirclip(13)frominfrontofthird/fourthgear(12).

4. Removethird/fourthgear(12).

5. Removethecirclip(11)frominfrontoffifthgear(8).

6. Removethethrustwasher(10),fifthgear(8)andthefifthgearbush(9).

7. Note(ormark)theorientationofthetwoBellevillewashers(7),thenremovethemfromtheshaft.

8. Removethethrustwasher(6).

Note:

• Unlessthebearingattheclutchendoftheinputshaftisdamagedorworn,itisnotnormallynecessarytoremoveitfromtheshaft.Thebearingispressedontotheshaftandisalsopressedintoitshousingandretainedbyasnap-ring.Thebearingandhousingareremovedfromtheshafttogetherandarethenseparated.

Supportthebearingandhousingonpressbars,thenpresstheshaftthroughthebearingandhousingasshownbelow.

1

= ><

1. Pressbars

2. Bearing/housing

10. Removethesnap-ringfromthebearinghousing.

10. Supporttheoutercircumferenceofthebearinghousingonpressbars,thenpressthebearingthroughthehousing.

Pressingoutthebearing

ServiceManual-RocketIll

8.19

Inspection

1. 2.	Thoroughlycleanthebearing	housingand
   	inspect for damage, scoring	and cracks.
   	Replacethehousingifnecessary

   Examineallgears,bearings andbushesandthrustwashersfordamage,distortion,chippedteethandwearbeyondtheservicelimits.Replacealldefectivecomponentsandalwaysusenewcirclipstoassembletheshaft.

2. Support thehousingonpressbarsasshownbelow8.ndpressthebearingfullyintothehousinginthedirectionofthearrow.

Assembly

Note:

• Lubricateeachgear,thrustwasherandbushwithcleanengineoilduringassembly.

Note:

• Thecirclipsusedontheinputshafthaveaflatsideandanangledside.Illustrationsthroughouttheassemblytextindicatewhichorientationofeachcirclipiscorrect.

1.Bearinghousing

2.Bearing

3. Retainthebearingwithanewsnapring.

Pressonlyonthebearinginnerracetopreventbearingdamage.

3. Locatethebearingandhousing totheinputshaft.Supporttheshaftonthepressbedandpressthebearingontotheshaft.

3

1. Positionanewbearingtothehousing.

1.Shaft

2. Bearing/housing

3. Press bars

5. Workingnowontheoppositeendtothebearing,slideonthethrustwasher(6).