Clutch/final drive

[matdave]

I have split my 2004 gs in half to replace clutch. The problem is when I started to put together I realized that the final drive shaft had come away at the final drive end and so i cant put the frame back together. Is there a way to reconnect the drive shaft to the final drive without taking the rear spring, swing arm etc apart.

Is it possible to remove rear brake caliper, rear wheel and separate the final drive at the rear boot.

Or would I be able to leave everything in place and use a rubber mallet to gently tap the drive shaft back over the final drive spline ?

Many Thanks

 

[G5RJO]

Undo the brake caliper.

Remove rear wheel - will take some balancing now or hanging off the ceiling.

Undo the top paralever bolt that fastens to the top of the final drive unit.

Tilt the final drive down pivoting on the bottom bearings.

This will expose the input shaft to the final drive, re-attach the splines (grease them whilst there and check for play on the splines and play in the input shaft, in/out and up/down, side to side).

Whilst it's all tilted down you may as well change the final drive oil (180ml).

Re-position the final drive and re-insert the top paralever bolt (Arguments prevail over replacing the nut with a new one, your choice).

Re-attach the brake caliper (whilst trying not to depress the caliper piston and squirting brake fluid everywhere as the line will obviously be open at the front end to facilitate the split.

Sounds harder than it is. Maybe 20 mins tops including the final drive oil change etc etc.

Roger.

 

[matdave]

Undo the brake caliper.

Remove rear wheel - will take some balancing now or hanging off the ceiling.

Undo the top paralever bolt that fastens to the top of the final drive unit.

Tilt the final drive down pivoting on the bottom bearings.

This will expose the input shaft to the final drive, re-attach the splines (grease them whilst there and check for play on the splines and play in the input shaft, in/out and up/down, side to side).

Whilst it's all tilted down you may as well change the final drive oil (180ml).

Re-position the final drive and re-insert the top paralever bolt (Arguments prevail over replacing the nut with a new one, your choice).

Re-attach the brake caliper (whilst trying not to depress the caliper piston and squirting brake fluid everywhere as the line will obviously be open at the front end to facilitate the split.

Sounds harder than it is. Maybe 20 mins tops including the final drive oil change etc etc.

Roger.

Thanks for the quick reply, really good instuctions - will get some replacement oil and give it a go.

 

[Pukmeister]

Don't forget to undo the rear wheel speed sensor before you remove the paralever bolt otherwise you could damage its cable, resulting in Speedo/ABS/Traction control faults.

 

[Bendy toy]

Take the swing arm apart anyway to check and grease the bearings.


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