Output Shaft - Disassembly

note
The numbers in brackets in the following text refer to the exploded view on Exploded View - Output Shaft.

Working from the opposite end to the drive sprocket, dismantle the output shaft as follows.

  1. Remove the output shaft bearing (1) and plain thrust washer (2).
  2. Mark one side of first gear to denote its correct orientation. Remove first gear (3) from the shaft, complete with the plain bush (4) which runs inside the gear.
  3. Remove the plain thrust washer (5).
  4. Mark one side of fifth gear to denote its correct orientation. Remove fifth gear (6) from the shaft.
  5. Remove the circlip (7) and splined thrust washer (8) from in front of fourth gear.
  6. Mark one side of fourth gear to denote its correct orientation. Remove fourth gear (9) complete with the splined bush which runs inside the gear (10).
  7. Note their orientation and remove the splined lock washers (11 and 12).
  8. Mark one side of third gear to denote its correct orientation. Remove third gear (14) off the shaft complete with the splined bush (13) which runs inside the gear.
  9. Remove the splined thrust washer (15).
  10. Remove the circlip (16) from in front of sixth gear.
  11. Mark one side of sixth gear to denote its correct orientation. Remove sixth gear (17) from the shaft.
  12. Remove the circlip (18) from in front of second gear.
  13. Remove the splined thrust washer (19).
  14. Mark one side of second gear to denote its correct orientation. Remove second gear (21) from the shaft, complete with the plain bush (20) which runs inside the gear.
  15. Position the output shaft (22) in a vice with soft jaws fitted. Tighten the vice to prevent the shaft from turning and release the tab washer (28) from the output sprocket nut (29), then release the nut.
  16. Remove the output sprocket nut (29), tab washer (28) and sprocket (27).
  17. Collect the output shaft seal (26).
  18. If it is found necessary to replace the large bearing (24) at the end of the shaft, use a press to remove both the bearing and output shaft sprocket spacer (25) together.
warning
When removing the output shaft bearing, always wear overalls, eye, face and hand protection. The bearing races are hardened and are liable to splinter if broken. Debris from broken bearings could cause injury to eyes, face and any unprotected parts of the body.