5.8
Final Drive/Brake System
12. Remove the cover fasteners.
13. Carefully remove the cover. Use a flat blade
scre
wdriver at the pry points to aid removal.
14. After removing the cover, note the two dowels in the
ch
aincase.
15. Inspect the cover gasket for damage. Inspect the
bea
ring and seal in the cover. Replace bearing if it no
longer rolls smoothly. Replace the seal if damaged.
16. Remove the chaincase sleeve from the jackshaft.
17. Remove the lower gear screw. Note th
e beveled
washer orientation.
18. Loosen the chain adjuster screw. Remove the
te
nsioner pad, upper and lower gears, and chain.
Chaincase Assembly
1. Thoroughly clean the chaincase, gears, and chain.
2. Inspect the tensioner pad for damage. Replace if
excess
ive wear is evident.
3. Install the gears and chain as a set.
4. Install the lower gear screw and beveled washer.
Ver
ify the beveled washer is installed dome side out.
5. Torque screw to specification.
6. Rotate the driven clutch forward to move all of the
ch
ain slack to the tensioner side.
7. Install the chain tensioner. Tighten the tensioner
scr
ew until there is 1/8" (3.175mm) chain deflection on
the backside of the drive chain.
8. Verify the tensioner screw washer is seated against
th
e chaincase, and then torque the tensioner screw
jam nut to specification.
9. Install the chaincase sleeve on to the jackshaft.
10. Inspect the cover gasket. Replace if cut or torn. Verify
th
e gasket is installed flush in the cover.
11. Install the cover making sure the cover engages the
two
dowels evenly.
12. Lightly tap on the cover with a soft-faced hammer to
se
at the cover.
SLEEVE
DOWEL
DOWEL
TENSIONER ADJUSTER
Lower Gear Fastener: 29 ft-lbs (40 Nm)
Tensioner Jam Nut: 21 ft-lbs (28 Nm)
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