Input Shaft - Assembly

note
The numbers in brackets in the following text refer to the exploded view on Exploded View - Input Shaft.Lubricate each gear, thrust washer and bush with clean engine oil during assembly.
warning
When using a press, always wear overalls, eye, face and hand protection. Objects such as bearings frequently break-up under load and the debris caused during break-up may cause damage and injury to unprotected parts of the body.Never wear loose clothing, which could become trapped in the press and cause crushing injuries to the hand, arms or other parts of the anatomy.
caution
Bushes and gears with oil holes must always be MISALIGNED with the corresponding oil holes in the input shaft. Reduced oil pressure and gear lubrication may result from alignment of the oil holes, which would cause premature wear of engine and transmission components.
caution
Removing the input shaft bearing from the shaft and its housing will damage the bearing and snap ring. Never reuse removed bearings or snap rings as use of damaged or weakened components could lead to engine and transmission damage. Also, check for damage to the housing itself.
caution
Press only on the bearing outer race to prevent bearing damage.
  1. Support the housing on press bars as shown below and press the bearing fully into the housing in the direction of the arrow.
    2. Bearing into housing ccbn_2

    1. Bearing housing

    2. Bearing

    caution
    Press only on the bearing inner race to prevent bearing damage.
  2. Locate the bearing and housing to the input shaft. Carefully support the shaft on the press bed, and using a suitable sleeve over the input shaft to ensure the bearing is pressed only on the inner race, press the bearing onto the shaft.
    3. Fit bearing to input shaft ccbo_1

    1. Sleeve

    2. Bearing/housing

    3. Press bars

    4. Input shaft

  3. Fit the plain bush (13) to the shaft.
  4. Fit fifth gear (12) to the input shaft as noted during disassembly, with the dog teeth pointing away from the input shaft bearing.
  5. Slide on the splined thrust washer (11).
  6. Fit a new circlip (10) to the input shaft ensuring that the clip is located in the circlip groove as shown below.
    7. Fit new circlip cdmo

    1. Fifth gear

    2. Thrust washer

    3. Circlip

  7. Fit the combined third/fourth gear (9) as noted during disassembly, with the larger gear facing toward fifth gear. Ensure that the oil hole in the input shaft DOES NOT align with the oil hole in the gear.
    8. warning
    If the oil hole in the third/fourth gear is aligned with the corresponding hole in the input shaft, engine oil pressure and gear lubrication will be reduced.Reduced oil pressure and gear lubrication will cause engine damage and could also lead to engine seizure resulting in loss of motorcycle control and an accident.
  8. Fit a new circlip (8) to the input shaft ensuring that the circlip is located in the circlip groove as shown below.
    9. Circlip for 3rd 4th gear cdmp

    1. Sixth gear

    2. Thrust washer

    3. Circlip

  9. Fit the splined thrust washer (7) to the input shaft and slide up the shaft until in contact with the circlip.
  10. Fit the splined bush (5) from sixth gear. Ensure that the oil hole in the input shaft DOES NOT align with the oil hole on the shaft.
  11. Fit sixth gear (6) as noted during disassembly, with the dog teeth facing third/fourth gear.
  12. Fit the splined and lock washers (4 and 3), ensuring the tabs in the smaller washer (3) locate in the slots in the larger (4) washer.
    13. Circlip for 6th gear cdmq

    1. Second gear

    2. Large splined lock washer

    3. Small splined lock washer

  13. Fit second gear (2) to the shaft as noted during disassembly.
  14. Fit the plain thrust washer (1) adjacent to second gear.