Replacing Rear Wheel Sprocket

To replace a worn rear wheel sprocket remove wheel from motorcycle as described in "Removing and Installing Rear Wheel." Disassemble brake drum from wheel. Chisel heads off all rivets and dowel pins from brake shell side and punch them out. If the rivet holes are not worn, use the rivet holes again. If the rivet holes are found slightly worn or elongated and drum is in good condition, drill a new set of rivet holes in drum flange midway between original dowel and rivet holes.

To drill new rivet holes, proceed as follows using new sprocket as a template for locating holes.

1. Drill a hole from the brake shell side.

Size: 1958 to early 1961 - 5/32 in. dia. drill Early 1961 and later - .1935 in. dia. (No. 10 drill) for 3/16" rivet

2. Drill one hole and insert rivet (do not head rivet).

3. Drill a hole directly opposite first hole and insert rivet (do not head rivet).

4. Drill remaining 14 rivet holes.

5. Remove rivets and separate sprocket from drum.

6. Remove burrs from newly drilled holes.

Whenever a rear wheel sprocket is replaced it is very important to drill new dowel holes to insure a press fit for the dowel pins. Use the new sprocket as a template and drill the four dowel pin holes 3/16 in. dia. for a press fit.

Position sprocket and drum on center support flange of Riveting Jig, Part No. 95600-33B. Proceed as follows, inserting and seating dowel pins first, and then rivets.

1. Insert dowel pins and rivets from brake shell side.

2. Use hollow driver and seat dowel pins and rivets at the same time driving sprocket and hub flange together.

Figure 2C-4. Starting Spokes in Wheel Hub Revised: 9-66

3. Use punch to flare dowel pin ends and rivet ends until heads extend 3/64 in. above sprocket face for 5/32 in. rivet size and 3/32 in. for 3/16 in. rivet size. Use concave end punch for small diameter rivets and dowel pins. Use flat end punch for larger diameter rivets.

4. Rivet opposite dowel pins and rivets until all are in place.

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