Service Manual
INPUT SHAFT
(Bevel
Pinion
Assembly)
Remove the woodruff key,
the
snap ring and shim
washers outside of the case. Push the input shaft out
of
lower transmission case half.
FIG.
15.
Remove Input Shaft
The
bevel gear
is
removed from the shaft by
removing the snap ring and pressing the shaft out of
the gear.
FIG.
16.
Input Shaft Disassembled
The
input shaft bushings are pressed out of the
case from the outside, pushing in.
If
replacement of
the
bushings
is
required, a new input shaft and O-ring
seal must also
be
installed, which
is
supplied as a
part of
a
service
kit.
CLEANING AND INSPECTION
Clean all parts in solvent, except O-ring seals,
switch components and other plastic parts. Inspect
all
parts for serviceability.
Check
the bevel pinion for
unusual wear,
which
indicates improper bevel gear/
pinion backlash. Inspect the gears, clutch collars,
sprockets and drive chain.
Check
the
"ears" on the
clutch collars and the recessed
sides
of
the drive gears.
Wear in
this
area may
be
the result
of
worn or bent
shift
forks, or
excessive
drive shaft end play.
Inspect the drive and output shaft bushings for
wear.
Also
check
that the bushing recesses, machined
into the transmission case halves, are not worn. Wear
in these recesses may indicate
loose
case
bolts,
or
excessive stress being applied to
the
transmission
during operation.
Check
the input, output and drive shafts for scor-
ing or damage to keyways. Light scoring can
be
re-
moved with a crocus cloth. Replace any shaft(s) with
damaged keyway(s).
OVERHAUL
INPUT SHAFT
New input shaft bushings are pressed into place;
the flanged bushing
is
installed from
the
inside and
the
straight bushing
is
installed from the outside.
Both bushings are pressed in flush with the case.
A
rubber O-ring fits between the bushings and should
be
installed after
both
bushings are pressed into
place (Fig.
17).
Install the woodruff key on the input shaft.
The
-'-
input gear
is
then pressed on the shaft, taking care to
align the gear and
#9
woodruff key before pressing.
._-
Install
the
snap ring onto the shaft
so
that
the
sharp
edge
is
away from the gear. Apply a light coating
of grease to
the
shaft and install the shaft into the
case and replace shim washers. Reinstall the snap
ring
so
that
the
sharp edge
is
away from the shim
washers. Using a
feeler
gauge,
check
between th'e
shim washers and the case to gauge
the
shaft end
play. Correct end play
is
.010-.020
in.
(.25-.50
mm).
Shim washers may
be
used in any combination to
achieve proper end play.
FIG.
17.
Input Shaft, Bushings