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loftus7608
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Joined: 09/01/2009
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I need some help guys. I have a drive shaft/gear box problem and I want to take them both out and ship them to Vech for repair. I started by taking the driveshaft out first by disassembling the rear shock - no problems there.

The drive shaft is now free from the shock - but how do I remove it from the gear box? Is there a trick to it?

Thanks, I appreciate any help.

(Yes I do have the repair manual but its a little gray in this area due to the age of bike.)

Thanks, Tom

Darryl.Richman
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If your driveshaft is free

If your driveshaft is free from the final drive -- I am assuming this is what you mean by "free from the shock", then you should be able to just pull back on it to remove it from the Hardy disk (the rubber hockey puck with a steel ring around it) and the Hardy disk just pulls off the output flange of the transmission.

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loftus7608
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Thanks Darryl. Correction, I

Thanks Darryl.

Correction, I should have said - I have only removed the rear wheel drive from the rear "shock" tower. The rear wheel drive and the drive shaft are still together as a unit. I thought I could remove these while together from the hardy disk and then the hardy disk from the output flange.

Do I need to take the rear wheel drive and drive shaft apart first in order to seperate from the hardy disk?

If not, with both together as a unit I did give a couple of good pulls and it won't release from the hardy disk. Is there a trick to it, or do you just pull real hard?

I can post pictures if needed.

Thanks again, Tom

Darryl.Richman
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It should just come off of

It should just come off of the Hardy disk. Nothing secures it to the Hardy disk other than geometry. I think there must still be something I don't understand about where you are in this process. That being the case, let me describe how I have disassembled this area in the past:

  • Remove the rear wheel.
  • Unscrew the hex cap from the top of the plunger ("shock") tower.
  • Loosen the pinch bolts, top and bottom and remove them.
  • From the bottom, using a large socket that just fits inside the lower frame plunger mount, tap the heavy steel guide post up and out the top of the plunger tower.
  • Push the rubber bung that acts as a dust cover forward on the driveshaft. Unscrew the bell cover on the nose of the final drive; beware, it has a left handed thread.
  • With the U-joint fully exposed, turn the driveshaft so that the yokes of the U-joint are directly vertical and horizontal. Then press inwards toward the bike's center line on the U-joint. This should turn the nose of the final drive inward and pull the driveshaft flange out of the Hardy disk.
  • Pull down on the spring above the final drive to free the threaded piece that the hex cap threaded onto. You should now be able to remove the final drive and the driveshaft as a unit.
  • Pull the Hardy disk free from the output flange of the transmission.
  • To separate the driveshaft from the final drive, find the pin that locks the two together, remove the nut that holds it in place and tap the pin out. The driveshaft will then slide off the male splines at the front of the final drive. BE SURE to mark the orientation of the driveshaft to the final drive splines and the direction that the pin went. These parts only reassemble one way!

Let me know if that helps clarify things.

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loftus7608
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Thanks Darryl

Thanks Darryl, I was stuck at your bullet number 6 and I think the alignment of the yokes of the U-joint was what I was missing to free the drive shaft. I'll try it tonight when I get home from work.

In your last bullet did you mean to say "seperate the driveshaft from the final drive"?

Cheers, Tom

Darryl.Richman
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Yes, I did mean to say that,

Yes, I did mean to say that, and I've edited the post so it's correct. Thanks for the catch!

Here are a couple photos to help; while looking these over, I realized that I had the order wrong for the pinch bolts in my previous post, so I've edited that, too. I believe the pinch bolts lock the guide post in place. (I have to admit that my memory is a bit fuzzy here, and these photos are 5 or more years old, so I haven't played with it for a while.)

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loftus7608
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Thanks Darryl, I was able to

Thanks Darryl, I was able to get it apart with these directions. Now on to taking the transmission out and then shipping them both to Vech.

Cheers, Tom

Darryl.Richman
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Pleased to have been of

Pleased to have been of service!

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