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SERYI-CAR

Błock up right wheel so it may be turned freely. Turn wheel until chain connecting link is visible through slot in outer chain guard halves. Disconnect connecting chain linkusing Chain Tool Part No. 95020-38 (supplied in rider accessory tool kit) or Shop Tool Part No. 95021-29. Attach end of new chain (if present chain is to be replaced), or old discarded chain (if present chain is being removed for cleaning or wear inspection) to rear end of present chain with connecting link. Rotate right wheel in clockwise direction, feeding old chain off sprockets and new chain onto sprockets. Keep loose end of replacement chain from slipping out of reach to chain guard with length of soft wire. Disconnect removed chain and connect ends of replacement chain with connecting link using Press Tool, Part No. 95020-66. Use new connecting link spring clip. Install clip with open end trailing direction of chain travel. Adjust chain as described in ^f,Adjusting Rear Chain."

When a second chain is not available to feed present chain off sprockets, remove chain as follows:

Remove the three bolts and two electrical conduit clamps from flange on upper half of outer chain guard. Remove three bolts from lower edge of lower half of outer chain guard. Remove three bolts from outer chain guard half joint and slip chain guard halves out of chassis.

Remove chain connecting link and feed chain off sprockets by revolving right rear wheel with gear shift in neutral.

To replace chain, feed one end over rear sprocket by turning wheel counterclockwise and other end over mainshaft sprocket by placing gear shifter in first gear and cranking engine. Connect chain ends and replace chain guard after adjusting chain.

DIFFERENTIAL AND AXLE

REMOVING REAR END

When repairs to rear axle housing, rear axle or dif-ferential become necessary, the entire rear enddrive assembly must be removed from chassis.

Disconnect and remove Servi-Car box and attach-ments as described in ”Removing Box from Chassis,” Section 2E.

Raise rear wheels free of floor with suitable support.

Remove rear outer chain guard and chain as described in ^,łRemoving Rear Chain.”

Remove cotter pins, nuts and washers securing inner chain guard to chassis.

Disconnect speedometer drive unit from differential housing.

Disconnect flexible brake linę between master cylinder and linę, at linę connection.

Disconnect wires at stop light switch.

Remove rear muffler clamp from frame.

Loosen nuts on the four bolts in frame clamp at each end of rear axle housing enough to allow clamps to slide freely on frame tubes. Slide rear axle assembly off frame members.

DISASSEMBLING AXLE HOUSING (Fig. 2B-7)

Remove hydraulic brake linę assembly (1).

Remove wheels and brake from axle housing as described in Section

Disconnect housing truss rods (2 and 3) at ends. Do not disassemble truss rods unless necessary for part replacement.

Remove axle housing clamp nuts and washers (4) and tap out five axle housing studs (5, 6 and 7). Remove left and right axle housings (8 and 9) from axle and differential assembly.

NOTĘ

If axle bearings (14 and 15), oil seals, or tapered bearing race reąuire servicing, con-tinue disassembly. If not, proceed to ”Dis-assembling Differential and Axle.”

Remove end bearing spring rings (10), thrust washers (11), oil seals with thrust bushings (12 and 13), roller bearing retainers with rollers (14 and 15), bearing races (16 and 17) and cup lock washers (18).

Remove bearing housing lock screw (19) and tum Tim-ken bearing housing (20) with bearing cup outer race (21) out of left axle housing. Bearing cup outer race in right axle housing may be pressed outonarbor press.

DISASSEMBLING DIFFERENTIAL AND AXLE (Fig. 2B-7)

Straighten ends of spring wire lock ring (22) and puli from holes in differential bolts. Remove nuts (23), washers (24), lock plates (25), bolts (26) and drive sprocket (27) from gear housing. Axle and differential halves may then be separated and right half of gear housing (28) lifted off axle. Rap wheel end of axle sharply on surface to slide drive sprocket down splines so axle lock ring halves (29) may be re-moved. Slip gear (30) off end of axle.

Tap differential gear shaft (32) out of case and lift out gear spacer (33) and two smali differential gears (34). Remainder of left axle assembly is disassembled in same manner as right. Timken bearings (38) and grease retainers (39) are pressed off differential housing only when replacement of either part is necessary.

Speedometer drive gear is a press fit on right axle and may be pressed off for replacement after meas-uring distance from end of axle to face of gear. Replacement part should be positioned exactly the same for correct gear mesh.

CLEANING, INSPECTION AND REPAIR (Fig. 2B-7) Clean all parts in grease solyent and dry. _x