Rear Output Shaft

Part 1 Of 2:

Part 2 Of 2:

DISASSEMBLY





1. INSPECT DRIVE SPROCKET THRUST CLEARANCE
Using a feeler gauge, measure the drive sprocket thrust clearance.
Standard clearance: 0.10-0.25 mm (0.0039-0.0098 inch)
Maximum clearance: 0.25 mm (0.0098 inch)
If the clearance exceeds the maximum, replace the drive sprocket.





2. M/T:
REMOVE HIGH AND LOW CLUTCH SLEEVE ASSEMBLY
a) Using a snap ring expander, remove the snap ring.
b) Remove the clutch sleeve and 3 shifting keys.
c) Using a press, remove the clutch hub, 2 key springs and key retainer.





3. A/T:
REMOVE HIGH AND LOW CLUTCH SLEEVE ASSEMBLY
a) Using a snap ring expander, remove the snap ring.
b) Remove the clutch sleeve.
c) Using a press, remove the clutch hub.
4. w/ A.D.D.:
REMOVE BEARING, SPACER AND DRIVE SPROCKET WITH FRONT DRIVE CLUTCH SLEEVE ASSEMBLY





a) Using SST and a press, remove the bearing.
SST 09555-55010





b) Remove the spacer and ball.
c) Remove the drive sprocket with the front drive clutch sleeve assembly.
d) Remove the needle roller bearing.
e) Remove the synchronizer ring.
f) Separate the front drive clutch sleeve assembly and the drive sprocket.
g) Remove the 3 shifting keys and 2 shifting key springs from the front drive clutch sleeve.
5. w/o A.D.D.:
REMOVE BEARING, SPACER AND DRIVE SPROCKET WITH FRONT DRIVE CLUTCH SLEEVE





a) Using SST and a press, remove the bearing.
SST 09555-55010





b) Remove the spacer and ball.
c) Remove the drive sprocket with the front drive clutch sleeve.
d) Remove the needle roller bearing.
e) Remove the front drive clutch sleeve from the drive sprocket.

INSPECTION





1. INSPECT REAR OUTPUT SHAFT
Using a micrometer, measure the outer diameter of the rear output shaft journal surface.
Minimum diameter:
Part A: 27.98 mm (1.1016 inch)
Part B: 36.98 mm (1.4561 inch)
If the outer diameter is less than the minimum, replace the rear output shaft.





2. INSPECT DRIVE SPROCKET RADIAL CLEARANCE
Using a dial indicator, measure the radial clearance between the sprocket and shaft with the needle roller bearing installed.
Standard clearance: 0.010-0.055 mm (0.0004-0.0022 inch)
Maximum clearance: 0.055 mm (0.0022 inch)
If the clearance exceeds the maximum, replace the drive sprocket, rear output shaft or needle roller bearing.





3. INSPECT FRONT DRIVE SHIFT FORK AND CLUTCH SLEEVE CLEARANCE
Using a feeler gauge, measure the clearance between the front drive shift fork and clutch sleeve.
Maximum clearance: 1.0 mm (0.039 inch)
If the clearance exceeds the maximum, replace the shift fork or clutch sleeve.





4. INSPECT HIGH AND LOW SHIFT FORK AND CLUTCH SLEEVE CLEARANCE
Using a feeler gauge, measure the clearance between the high and low shift fork and clutch sleeve.
Maximum clearance: 1.0 mm (0.039 inch)
If the clearance exceeds the maximum, replace the shift fork or clutch sleeve.

REASSEMBLY
1. w/ A. D.D.:
INSTALL FRONT DRIVE CLUTCH SLEEVE ONTO DRIVE SPROCKET





a) Install the front drive clutch sleeve onto the drive sprocket.

HINT: Make sure to install the clutch sleeve in the correct direction.





b) Install the 3 shifting keys and 2 springs.

NOTICE: Position the key springs so that their end gaps are not aligned.





2. w/o A.D.D.:
INSTALL FRONT DRIVE CLUTCH SLEEVE ONTO DRIVE SPROCKET
Install the front drive clutch sleeve onto the drive sprocket.

HINT: Make sure to install the clutch sleeve in the correct direction.





3. w/ A.D. D.:
INSTALL DRIVE SPROCKET WITH FRONT DRIVE CLUTCH SLEEVE ASSEMBLY AND SPACER
a) Apply gear oil to the shaft and needle roller bearing.
b) Place the synchronizer ring on the spline and align the ring slots with the shifting keys.
c) Install the needle roller bearing in the drive sprocket.
d) Install the drive sprocket with the front drive clutch sleeve assembly.
e) Install the spacer to align it with the ball.





4. w/o A.D.D.:
INSTALL DRIVE SPROCKET WITH FRONT DRIVE CLUTCH SLEEVE AND SPACER
a) Apply gear oil to the shaft and needle roller bearing.
b) Install the needle roller bearing in the drive sprocket.
c) Install the drive sprocket with the front drive clutch sleeve assembly.
d) Install the spacer to align it with the ball.





5. INSTALL BEARING
Using SST and a press, install a new bearing with the outer race snap ring groove toward the rear.
SST 09316-60011 (09316-00011, 09316-00071)





6. INSPECT DRIVE SPROCKET THRUST CLEARANCE
Using a feeler gauge, measure the drive sprocket thrust clearance.
Standard clearance: 0.10-0.25 mm (0.0039-0.0098 inch)





7. M/T:
INSERT HIGH AND LOW CLUTCH HUB ONTO CLUTCH SLEEVE
a) Install the clutch hub and 3 shifting keys onto the clutch
sleeve.
b) Install the 2 shifting key springs under the shifting keys.

NOTICE: Position the key springs so that their end gaps are not aligned.





8. A/T: INSERT HIGH AND LOW CLUTCH HUB ONTO CLUTCH SLEEVE
Install the clutch hub onto the clutch sleeve.
9. M/T:
INSTALL HIGH AND LOW CLUTCH HUB ASSEMBLY





a) Using SST and a hammer, drive in a new key retainer.
SST 09316-60011 (09316-00011)

NOTICE: Be careful not to deform or damage the key retainer.





b) Using a press, install the high and low clutch hub assembly.





10. A/T:
INSTALL HIGH AND LOW CLUTCH HUB ASSEMBLY
Using a press, install the high and low clutch hub assembly.








11. INSTALL SNAP RING
Select a snap ring that allows the minimum axial play and install it to the shaft.