swapping output shaft 5th gear bearing

[motoqueiro]

OK
I'll post the work I've done today, after I realize, a week ago, the bearing was about to go bummm
It's a 10 year old bearing with 140000 km in it on an every day ride bike

remove belt

with a special home made tool, lock the pulley and remove the locking plate and pulley "left" nut

Remove pulley, pulley spacer, oil seal, and retaining ring

Then remove the bearing, I've made a grab so to go in the bearing and be able to pull it out

yank it out

now for the new bearing

did a pusher for it to

instal the retaining ring the quad seal oil seal pulley spacer and pulley

using the locking tool, fit the left thread nut and tight it good, fit the locking plate and tight the two bolts

and finally fit the belt and your done

can go and relax now

 

[motoqueiro]

just to have an idea on what the bearing looked like

it does a noise like a low tire or a dirt bike tire on pavement, at first I thought it as the belt noise on the pulley, then I decided to remove the pulley and spacer to try and have a look see, and I saw the spheres had pits on them, the rest is history

 

[d_adams]

[up]

Nicely done, my bearings were destroyed, had to split the cases to inspect for possible damage, so doing it this way wasn't an option for me.

 

[motoqueiro]

The day I have to split the cases on my buell, is the day she will stop been my daily ride to work, and sadly, need a new one [sad]

 

[Todd]

I'm going to be doing this but wonder why you can't just hold the front sprocket with the belt and rear brake?

 

[Chicknstripn]

That will transfer a lot of stresses through the gear box in a way that the gear box was not designed for. That's another reason why the manual warns against using an impact wrench.
Trust me, you want to take every precaution you can to protect those gears.
Once you split those cases to rebuild the tranny, you don't want to do it again!

 

[mylesq]

do you know what size the two bolts for the locking plate are? i sold my 5doro pulley cover, and went to put the stock one on, and can't find the factory bolts

 

[TPEHAK]

[up]

Nicely done, my bearings were destroyed, had to split the cases to inspect for possible damage, so doing it this way wasn't an option for me.

Have you found any damage?

 

[Cooter]

After 2 years I hope so!

Thanks for bringing this thread up though, It's a nice post!

 

[njloco]

That was done all wrong had to be wrong, he'll be lucky if it lasts a day, I would never copy this technique. There was absolutely no beer consumed, what a wasted opportunity !

 

[TPEHAK]

Why?

 

[Cooter]

Because Beer, you square:angel: LOL

 

[njloco]

He'll eventually loosen up, it's an age thing most of the time. Tpehak, you do such nice mods but, they're all wrong also, due to lack of beer !

I do pray for you !

 

[livefstdieyng]

So just a quick question for the experts, is this what you're supposed to find behind that pretty little cover on your xb? This is off a 99 cyclone I just picked up. I'm trying to figure out what's going on here....

 

[Cooter]

Yes. Whats your question? How to remove it?

 

[livefstdieyng]

Well no, there was no cover on it. I was a little worried because you can see the needles in the bearing. I thought it was falling out. What is that cover called?

 

[TPEHAK]

Looks like the bearing walked out.

 

[David Borthwick]

Does this method work? It does put a lot of stress on the gearshafts etc using the puller and pusher but so much easier than splitting the cases. What are the dimensions of the pullers, if it works then I think it is easier to get one made than splitting the cases.

 

[Cooter]

The way his puller and pusher are designed, there isn't a whole lot of stress on the output shaft.

The bearing isn't technically a "press-fit" on the shaft or case, so it's not that hard to move. On removal, his long handle is only hand tightened and pulled on. A slide hammer would be easy as well. On install, his plate supports itself against the shaft. Don't forget the snap ring!!!

I would advise against any linear 'whacking' of the output shaft with a hammer for any reason. It's supported well, but you don't want to add any clearances that way:upset:

 

[user_deleted]

What size is the pulley nut? Will need to get a socket to fit.

1-7/8th inch socket OR 48mm socket if you're a "furiner".
you're going to need a hell of alot more than a socket that fits to do this job.
moto hasn't been on this site in approx. 1-1/2 years but you can always ask him your assorted questions instead of flooding this thread with them.
DO NOT use an air impact driver on this nut.
you MUST lock the pulley with either a factory style device or something "home-made" mimicking same.
threads are LEFT HAND THREAD meaning TURN RIGHT TO LOOSEN the nut.
it's factory installed with red loctite meaning a bit of heat must be applied to the nut to break the bond.
i have loaned both the locker tool and the socket with t-handle attached to several board members. deposit required.