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 by removing 8 bolts. 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 9/64 in. hole from the brake shell side.

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.

1. Bearing lock nut

2. Bearing oil seal

3. Bearing outer spacer

4. Ball bearing

5. Bearing washer

6. Bearing spacer

7. Ball bearing (1962 & earlier)

7 A. Unshielded ball bearing (1963 & later)

8. Bearing spacer (1962 & earlier)

8A. Bearing spacer washer (1963 & later)

9. Grease retainer (1962 & earlier) 9A. Shielded ball bearing (1963 & later)

Figure 2C-12. Rear Wheel Hub - Exploded View

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. 95600-33A. Proceed as follows, inserting and seating dowel pins first, and then rivets.

1. Insert dowel pin and rivet from brake shell side.

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

3. Use concave punch and flare dowel pin end. Head rivet end until head extends 3/64 in. above sprocket face.

4. Repeat steps 1, 2 and 3 seating opposite dowel pins and rivets until all are in place.

This procedure will prevent distortion of sprocket.

Install brake drum on wheel and wheel in motorcycle as described in "Removing and Installing Rear Wheel."

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