Rubber Boot - Replacing

[BegesRus]

Riding to get MOT - the damed rubber split on the way!
With much help from my mate Les the job got done like this

-

Temp duck-tape removed
Remove rear wheel
Exhaust and collector box
Battery Box
Drain and remove Bevel Box

Clutch arm
Swinging arm

Para lever
Brake cable


The ofending item stripped

The swinging arm can be removed with the driveshaft insitu

Tie the bearings in place so as not to mix them

Clean up s/a ready for install

New boot being fitted

Slip s/a back into position

Like this

Install bearings each side

Pre-load the bearings

To correct Tourqe

Set gaps equal on each side - mine was 3.7mm

You have to do this repeatedly when you back off the torque to the final setting

Tighten the lock nuts

Fit the boot to the Gearbox - this takes patience to say the least - no grease - no hot water just keep at it! swearing helps a lot

Lube the splines and refit bevel box - a bit tricky to get engaged

Jobs done

Recheck all bolts are tight and set to toruqe

Hope this last for many years and it's an enormous job for a piddly part

My thanks to Les without his help I would be running round with duck tape!

 

[Rob Farmer]

Thats a great write up

 

[Ogmios]

yes Very Helpful write up - the pics help me a lot.
i have to strip mine (SOMEtime soon, please gods! ) to suss what's rumbling in there.
Thanks for taking the time and trouble.

 

[Voyager]

I have to strip mine (SOMEtime soon, please gods! ) to suss what's rumbling in there.

So it wasn't the exhaust mounting bobbin then . . ???


Bob.

 

[Voyager]

Riding to get MOT - the damed rubber split on the way!
With much help from my mate Les the job got done like this . . . . .

So why remove the bevel drive ? ? ?

Is it because you didn't want to unbolt the prop shaft from the gearbox output flange and the only way to get the splines connected afterwards is with the drive off ?

Or were you going to do a full oil and bearing service anyway ?

I undo the propshaft first - standing on the back brake while I use the 10mm ring spanner. Then remove the swing arm complete with bevel drive and rear shock attached (torque arm and brake cable have to come off).

The worst part is getting the gaiter back onto the gearbox. It helps to have the collector box removed, but it is possible to do it with the exhaust in place - it just requires a lot more bad language


Bob.

 

[Ogmios]

So it wasn't the exhaust mounting bobbin then . . ???
Bob.

only ordered this week - picking it up tomorrow.
cost; €9 .
value; priceless if it solves the problem!

so - with crossed fingers and toes and eyes.... (which is going to making fitting it awkward )..... i shall find out.*


*i'm NEVER that lucky / but ever hopeful

 

[Steptoe]

So why remove the bevel drive ? ? ?


The worst part is getting the gaiter back onto the gearbox. It helps to have the collector box removed, but it is possible to do it with the exhaust in place - it just requires a lot more bad language


Bob.

I also wondered why dismantle everything - the exhaust can all stay in place as well. I just undo/remove the swingarm bolts, undo the shaft bolts, move the swingarm/shaft back an inch and slide the gaitor in place.

The trick for getting the gaitor in place is leave it until last, take the bike off the stand and have someone sit on it. This evens out the angle of the swingarm and gearbox and gaitor just pops in place

 

[Voyager]

The trick for getting the gaitor in place is leave it until last, take the bike off the stand and have someone sit on it. This evens out the angle of the swingarm and gearbox and gaitor just pops in place

When doing it alone, I undo the shock top mounting and put wood blocks under the rear wheel to line everything up.

Bob.

 

[(RIP) pastyman]

Watching rob doing this at the Weekend, He made a simple tool for hooking the gaiter around the gearbox flange. looked a bit like a small dockers hook. made out of a bit of welding rod size wire. Didnt hear him swear a lot.

 

[John Armstrong]

Watching rob doing this at the Weekend, He made a simple tool for hooking the gaiter around the gearbox flange. looked a bit like a small dockers hook. made out of a bit of welding rod size wire. Didnt hear him swear a lot.

Did it look something like this:

http://buy1.snapon.com/catalog/item...group_ID=17516&store=snapon-store&dir=catalog

I have a similar one and it's worth its weight in gold

 

[toadjam]

snap on hooktool

i use a snap on radiator hose tool , similar sort of thing .
there are cheaper versions used in car windscreen fitting , but i have to feed my snap on addiction .

 

[John Armstrong]

i use a snap on radiator hose tool , similar sort of thing .

Snap

 

[Beemerboff]

I bought a pair of long handled (11") needle nosed pliers , the sort with a 45 degree bend about an inch and a half from the business end.

Couldn't imagine what I would use them for but they were almost giving them away---.

They are just the tool for fitting the boot and they have proved handy a few times - the 45 bend acts as a fulcrum for levering things up and out.