I. TRANSMISSION AND DRIVELINE REMOVAL PROCEDURE
Section 1, Procedure for transmission removal:
1. Elevate and secure the bike firmly to a non-moving stand. Bike should be elevated
so that the rear wheel is not touching the ground.
2. Remove all fiberglass side covers from the bike.
3. Shut fuel valve. Disconnect fuel line and plug, if necessary. Remove fuel tank.
4. Remove front seat. This is accomplished by removing the two attaching bolts on
each side of the front seat bracket and the bottom shock absorber attaching bolt.
The whole assembly can be removed and put aside.
5. If transmission and driveline need to be removed, the rear wheel and rear fender
will need to be taken off the bike. If only the transmission needs to be removed,
the rear wheel may stay intact.
See Section 2 for Drive Line Removal.
6. Remove the rear drive chain by locating the master link and separating it from the
chain.
7. Remove the rear driveline roll pin. (If transmission and driveline are to be taken
out as one unit, leave roll pin attached for ease of disassembly.) This is done by
inserting a pin punch into the roll pin access hole (located under the front seat,
which was removed), and driving the pin straight downward. Note: Rotate rear
wheel until hole lines up.
8. Remove drive belt.
9. Remove driven clutch. Loosen the three Allen screws behind the clutch. Note:
Driven clutch may be frozen on to the shaft. A small piece of wood and a mallet
from behind the clutch should ease removal. Care must be taken, not to damage
clutch. Use pry bars if necessary.
10. Remove muffler header pipe. (Loosen two 12mm nuts. Pull muffler off engine seat.
Pull muffler out of sleeve).
11. Remove rear brake caliper assembly. Take caution not to undo the brake line
from the spring assembly. Disconnect cotter pin and back off brake tension.
Remove brake caliper assembly and brake bracket as a complete unit. (Remove
the two 1/2 “ bolts under the brake disc.). Slide Brake Disc off shaft. Take note
the way the caliper and brake disc came off for reassembly.
Section 7 Repair Procedures
18
ROKON INTERNATIONAL, 50 Railroad Ave., Rochester, New Hampshire 03839, U.S.A. Copyright 2004
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