Mk3 Rear Wheel Reassembly - Need some Guidence

Hi Guys,

I've reassembled the rear wheel of my Mk 3 to the point of attaching the LHS assembly, and am at a loss to understand the order in which the parts are attached. The wheel is complete to include the lockring, sprocket, sprocket bearing, and circlip. What's left are the following:
1 The speedo drive 06-5540 (new)
2. The sprocket bearing spacer 06-5547 (.79 ID, 1.00 OD, .37 H)
3. The dummy shaft 06-5552
4. The washer 06-5459 [Edit: The correct part number is 06-5549 - L.A.B.]

If the dummy shaft is assembled first, and the speedo drive forced over the dummy shaft, the lockring/drive cogs do not mate; they are held apart by the large diametr section of the dummy shaft. If the spacer is fitted first, and then the speedo drive, and then the dummy shaft, the speedo drive mates properly with the lockring cogs, but there is very little clearence between the drive cable and the chain sprocket, and there appears to be only a few engaged threads between the two shafts. The manual is of little help. What's the right assembly order?

Rick,

I've read through what you've said a number of times, but somehow I don't quite understand what you mean?



I always treat the wheel as two sub-assemblies, basically because it's easier to assemble and fit the sprocket with the dummy axle first, rather than attempt to fit the whole wheel assembly in one go? (Others of course, may disagree with that?)



OK, so you have the sprocket oil seal, bearing and circlip already installed in the sprocket in that order, as it is shown in the factory workshop manual exploded diagram which I believe to be correct, and not as it is shown in the parts book diagram with the oil seal on the outer side of the bearing?

As I understand it, the dummy axle is inserted into sprocket bearing from right to left, and then the 06-5547 spacer fitted onto the dummy axle next to the bearing, followed by the speedo drive box taking care to locate the drive box dogs into the sprocket drive slots, and then the 06-5459 [06-5549] washer last as shown below?



However.....

If I assemble the parts in that order on my own MkIII sprocket, then inner face of the speedo drive box is forced into contact with the shoulder on the sprocket when the dummy axle nut is tightened, so I have the 06-5459 an additional washer fitted between the sprocket bearing and the 06-5547 spacer. This works for me, as it spaces the drive box away from the sprocket so that it doesn't bind, but it may not be necessary on other MkIII rear sprockets?
I remember remarking recently in another thread that I didn't have the 06-5459 [06-5549] washer fitted, but now I remember that I had changed its position.



I then fit the sprocket assembly to the swing arm with the chain adjuster, axle nut and washer and just nip up the nut, then fit the chain over the sprocket and join both ends with the split link, or the chain could be fitted over the sprocket first, as it really doesn't make any difference. The chain tension can then be set before the wheel is fitted if required.
There is very little clearance between the speedo cable and the sprocket, and I'd recommend that you cable tie it to the swing arm to keep it away from the sprocket.

Then fit the wheel, by hooking the drive plate onto the sprocket paddles, then install the caliper plate, right hand adjuster, and main axle with its washer and fully tighten the dummy axle nut and axle after the wheels have been lined up.

Thanks, LAB

Once again you've pulled me back from the manual abyss. The center hole in my replacement speedo driver was 0.030" undersized, and would not accept the dummy shaft. A little reaming and following your instructions left me this morning with an assembly I could believe in. Final assembly via your instructions will have to wait until this evening, when I can gracefully exit family Easter celebrations and renew my spiritual connection to a vintage motorcycle in my chapel/garage.

Thanks again for your patient and complete response.

Re:

rick in seattle said:

Thanks, LAB

Once again you've pulled me back from the manual abyss. The center hole in my replacement speedo driver was 0.030" undersized, and would not accept the dummy shaft. A little reaming and following your instructions left me this morning with an assembly I could believe in. Final assembly via your instructions will have to wait until this evening, when I can gracefully exit family Easter celebrations and renew my spiritual connection to a vintage motorcycle in my chapel/garage.

Thanks again for your patient and complete response.

Click to expand...

Same build - Mark 3
Same problem - looking at the parts not the shop manual exploded view wondering how the oilseal is going to fit over the circlip
Same sage advice - L.A.B. - thank you!!!!
Same night - Easter Sinday - albeit 3 years later
Same result - properly fitted rear sprocket that I will know went together correctly