2003 Jackshaft up date with pic.

[Skydog]

Hey guys i thought this could help us all out! Here is a pic of the new sleeve and locking nut. The old 03 style i am holding in my hand. I pulled the jackshaft out. Took a long 1/2 EX with a socket on the end and tapped the old bearing out. Very easy, i am going to put the chain case all back togeather frist to set the right bearning depth with the new locking coller.

Now this is the right order that the new nut, bearing and locking collar go on right?? I am sure it is but would like to hear it from some one, if so how did you get to the new nut on the back side to get it snug? A long chesiel?

Thank you Skydog

 

[ecopter]

Looks right to me. On the secondary side (in one of the grooves of the threaded collar) I wedged the 'handle' end of a long file into the slot on the collar and the 'file' end of the file into the tube support around the footwell. I then used a long angled pry bar and a mallet to turn the nut onto the collar; one 'castle' at a time. (The file wedged into the collar kept it from turning while I was threading the nut on the collar. Unorthodox? Maybe, but it worked.

Jon

 

[ecopter]

Also, if you look on the '04 microfiche, it shows the use of different spacers between the bearing and the secondary as compared to the '03 RX1. When I ordered the collar and nut from Port, Kevin indicated the new spacers are a required part of the change. Just thought you might want to know....

Jon

 

[TurboTony]

Ahh, now it makes more sense.

I was at the dealer yesterday and recived several blank stares when I asked for the update parts required.

Now silly question time. I just pulled off my chaincase with kackshaft installed. Mainly because I couldn't hold the shaft to get the nut off the top gear.

Do I have to disassemble all that to get the shaft back in correctly or can I just put it back together with the jackshaft in the chain case?

Tony

 

[ecopter]

I'd say if you got shaft off and it's still connected to the chaincase via the upper nut, there's no need to remove it all to reinstall it. At least you'll know everything's in place on the chaincase side and it will all be in alignment.

Jon

 

[rx-1 blue reverse]

thank you for this post I need this info

 

[Skydog]

Yes you are welcome!

Skydog

 

[Skydog]

Also, if you look on the '04 microfiche, it shows the use of different spacers between the bearing and the secondary as compared to the '03 RX1. When I ordered the collar and nut from Port, Kevin indicated the new spacers are a required part of the change. Just thought you might want to know....

Jon

Bought the two washers one looks just like a plain old washer and one has a stepped side dont realy know why or what for? I put them both on and checked my offset with a Kent-moore 15MM offset tool. My secoundary was out way to far pulled one washer from the back. Still out to far had to pull both washers out and put a real thin one on the back to get offset right!! So i dont know how your offset is right??? Or what Yamaha wants you to do? I think i will leave it where it is, the plain old thin washer should be just fine.


Skydog

Skydog

 

[ecopter]

That washer with the stepped side goes with that side right against the new locking collar. If everything on the chaincase side is assembled correctly, it will allow the correct amount of jackshaft length to remain on the secondary side. Once you put the collar on and tighten the new locknut, slipping the stepped washer on will make for a perfect fit within that new threaded collar. I simply followed the order shown on the '04 parts microfiche by placing the washers as shown in that specific order on the sled. If you notice, the washers between the secondary and the jackshaft bearing aren't optional. Only the shimming washers between the secondary and the retaining bolt to hold the secondary allow to use optional sizes for proper shimming.

Some one might correct me here, but with this new set up (from '04 on, and with the stock clutching) you will probably use the washers as indicated in the parts catalog.

Also, if you've noticed, on the '03 RX1, it does allow you to use different thickness washers between the secondary and jackshaft bearing. My assumption here is that the new threaded collar changed the distance and that it's required to use the two noted washers.

I guess in the end, ya gotta do what ya gotta do to get it to be correct.

Sorry to ramble on,
Jon

 

[ecopter]

One other question, when you had both washers on, how much play did you have on the retaining bolt end of the secondary? I'm showing the sheave free play on the outside of the secondary to be 1.0 to 2.0mm.

In the '03 service manual, I do notice you can adjust the offset by changing the washers on the inside of the secondary. Is this also the case with the '04 and up models?

jf

 

[Skydog]

Yea it is funny. I have the same washer on the back side of the secoundary as i did with the 03 set up. The new collar does not stick out any more than the old set up. I know it is all assembled right.?? The washer with the stepped side goes up to the new locking collar, but it rides on the inner bearing race so there is no way to move the bearing back any? And the jack shaft is the same depth that it was before i took it apart. (i marked it) And that is why i have to use the same shims.. MMMMM i wounder??



Thank you Skydog
P.S. I will go get a pic of sled.

 

[Skydog]

Here is a pic you can see the new collar is flush with the bearing. Just like the 03 set up was, wonder why they did not use a stepped washer on the 03 set up? It is realy the same thing on the clutch side of the bearing. The just added a nut on the back to hold the collar in place.??? Just thinking out loud, dont want this update to bite me in my As-!!

 

[Skydog]

One other question, when you had both washers on, how much play did you have on the retaining bolt end of the secondary? I'm showing the sheave free play on the outside of the secondary to be 1.0 to 2.0mm.

In the '03 service manual, I do notice you can adjust the offset by changing the washers on the inside of the secondary. Is this also the case with the '04 and up models?

jf

i will go see!

 

[Skydog]

Ok if i put the 04-05 washer set up behind the secondary and use the three washers in the pic. there is no play. One big washer just for the bolt and two smaller ones that will slide over the center spacer.

 

[Skydog]

Now here is how far off my offset is with the 04-05 washer set up in place behind the secondary.