Having trouble with gear install

Karman · Post by **Karman** » Fri Jun 13, 2008 8:38 am

Here's my problem - I pressed my 8.44 on yesterday and set about putting it back together last night. Everything went ok until I started bolting the gear cover back on. With the two bolts closest to the shaft, anything more than finger tight, it causes the whole assembly to drag as if the rear brake were on. With all five bolts on there tight, it just about locks the rear wheel up. I'm absolutely certain they're not overtight. (I even checked the service manual for a torque spec and there doesn't seem to be one)

I'm thinking I have a problem with the thrust washers and that I may have put them in the wrong place (although it looks correct based on the manual). I have a total of three - two metal, and one thicker white plastic. I put the plastic one in first here:

And the two metal thrust washers were put on last and left facing you as you put the cover on:

Is this correct? If so, is there anything else I could have done wrong? Again, I'm absolultely sure I'm not over tightening the cover. It starts to drag before the bolts are even seated and just gets worse from there.

This is the manual page with the parts breakdown:

It seems like I have it correct, unless the plastic one is supposed to be in the front. Unfortunately the manual doesn't specify which thrust washer is which. And I have it assembled the way I remembered it.

mopedman · Post by **mopedman** » Fri Jun 13, 2008 8:55 am

what year is your bike ?

Karman · Post by **Karman** » Fri Jun 13, 2008 9:06 am

2001 Elite S

mopedman · Post by **mopedman** » Fri Jun 13, 2008 9:18 am

were those washers on there before??? cuz if you look at the pic it don't show any and when i took mine apart on my 1995 there was one small washer on the outer of the small gear

mopedman · Post by **mopedman** » Fri Jun 13, 2008 9:21 am

also in advanced tec docs it dosnt say any thing about washers in the gear installation http://www.hondaspree.net/phpBB2/viewtopic.php?t=4489 and i know docs is right cuz i have rode his bike

Karman · Post by **Karman** » Fri Jun 13, 2008 9:31 am

Yes - they were already on there.

If you look at the manual picture they're circled in red. They're ouside of the boxed sections meaning they're applicable to both model series (I assume). They're also mentioned in the service manual in the final drive section. I also saw them in the parts diagram last night when I was trying to distinguish between the metal and plastic ones (it was no help). It did strike me as strange that they weren't mentioned in Dac's tech doc.

Is the one you have metal or plastic?

mopedman · Post by **mopedman** » Fri Jun 13, 2008 9:35 am

just one metal one my bike runs fine like that.... im not telling you to take them out..... but my bike runs great like it is and it only has one metal one on the out side of the small gear

Karman · Post by **Karman** » Fri Jun 13, 2008 10:00 am

Weird - Dac has none, you have one and I have three. I think I'll check the parts diagrams some more for different years and see if there are any changes in the numbers for the covers, washers, etc. If I can pull them out (particularly the thick plastic one which is probably the root of my problem) I will.

mopedman · Post by **mopedman** » Fri Jun 13, 2008 10:03 am

personally i would take that b**** right out, but i didn't want to tell you to then have something happen

CharlotteSpreeRider · Fri Jun 13, 2008 10:05 am

I think the answer may be, the more times something has been taken apart, the more likely the chances of parts not getting put back in, i.e., "extra parts".

-aseigler

mopedman · Post by **mopedman** » Fri Jun 13, 2008 10:06 am

yup... i call that geto wait reduction

Elite1998 · Post by **Elite1998** » Fri Jun 13, 2008 11:30 am

mopedman wrote:just one metal one my bike runs fine like that.... im not telling you to take them out..... but my bike runs great like it is and it only has one metal one on the out side of the small gear

Same here

Dac · Post by **Dac** » Fri Jun 13, 2008 11:36 am

hate to let you down but dude, i dont have a clue.

that was like last year and i cant hardly remember what gear went in first, let alone washers.

mopedman · Post by **mopedman** » Fri Jun 13, 2008 11:53 am

just take the lthing out already

jstone · Post by **jstone** » Fri Jun 13, 2008 4:27 pm

If something goes wrong, mopedman has a nice set of 7:1 gears he'll send you

. LOL