darkcider

On 5/18/2016 at 3:35 PM, BiKenG said:

If replacing the shaft yourself, some advice. Follow the procedure in the manual. This states that the shaft should be fixed onto the final drive unit (so the snap ring has snapped into place) and then insert that whole assembly into the bike. However this means holding the final drive unit with one hand while trying to push aside the rubber boot and feed the UJ onto the gearbox output shaft, while holding the snap ring at this end open with a pair of circlip pliers. Well if you've been counting, that's 3 hands at least, not to mention the impossibility of holding the final drive unit up with one hand. Man, it's heavy.

 

So I took the obvious alternative method of installing the drive shaft shaft into the swingarm and onto the gearbox shaft first, then pushing the final drive unit onto the CV  joint output spline and finally onto the swingarm studs and avoid having to manhandle the final drive unit and shaft together as one assembly. Ha... I thought.

 

Don't bother even trying.

 

It is IMPOSSIBLE to push the final drive unit onto the shaft spline. Even with plenty of good grease, it simply won't go on and just pushes the shaft into the swingarm instead. There is no way to hold the CV joint to stop it all disappearing into the S/A as soon as you try to push on the final drive unit. If only they'd put a small step in the CV joint or shaft to hold it while pushing on the final drive unit...

 

But they didn't. So after pulling it all out again, if fitted the shaft into the final drive unit and then installed it all together as one assembly. A box, or something similar onto which the final drive unit could rest approximately in position, while working on getting the UJ onto the gearbox output shaft is I'd say essential, but then it wasn't actually as bad as I expected. The rest is a piece of cake anyway, so overall it's not a particularly hard job - if you follow the manual

 

Well, it all helps to pass the time while it rains outside 

So, although I've supposedly had the new shaft fitted by a local dealer, I can't find any punch marks on the subframe, or below the first digit of the frame number, so I'm curious as to what has actually been done.

Also, ever since the work was carried out, my rear brake calliper carrier has been pretty much touching the brake rotor and  although the bike runs great, I have no confidence in the rear brake, as the odd time I've used it, it's ended up binding due to heat and expansion.  (See photo of just how close the clearance is on my rear hub - it's as though the disc carrier is seated too far into the FD).

So, I'm replacing the final drive with a different one, where the calliper carrier is in the correct position.  Which brings me to the nub of my post:

When removing the final drive/shaft, how the heck do you remove the shaft from the FD pinion gear??  I've followed the manual, turn slowly while gently pulling on the CV joint, but it's not budging.  How much force does one need to put in to separate the two??