DRESSTA TD-25M EXTRA, Service Manual, Page: 506 / 595

SECTION 14
SUSPENSION
Page 12
TD-25M EXTRA DRESSTA
FRONT IDLER
1. Remove hardware and fork (1, Fig. 14.12) from front idler (4). Using large pry bar, relief block
clamping tension on front idler (4). Remove the blocks (2 and 5). Remove the pin (3) from idler
shaft.
2. Remove the plug (10) and drain oil from front idler. Remove the retaining ring (4) and slide seal
retainer (1) with O-ring (2) and half seal kit (3) off shaft (11). One half of the seal kit (3) will
remain in bushing retainer (5). Remove second half kit seal (3) from bushing retainer (5) and
keep both halves together. Repeat this step for other side of idler.
NOTE: Keep original mated metal rings as a set. Do not mix a metal ring from oil seal in one side
of idler with one from oil seal on other side.
3. Remove mounting hardware and bushing retainer (5) with O-ring (6) from each side of idler.
Remove washer (7). Position idler in press and remove shaft (11). Bushing (8) are a press fit in
front idler housing (9) and must not be removed unless replacement is necessary.
9. INSPECTION AND REPAIR
1. It is recommended that new O-rings be installed whenever the front idler is disassembled for
service.
2. Wash all parts thoroughly in a suitable solvent. Dry thoroughly with compressed air.
3. Inspect the idler shaft, bushing, washer and idler for cracks, scores or excessive wear.
4. Check the clearance limits given in Fig. 14.15.
5. Inspect the blocks (2 and 5, Fig. 14.12).
Fig. 14.15. Front Idler Bushing Clearances
A. Distance between seal retainer surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170.45
±
0.2 [mm]
B. Width of idler shaft bushing surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164.1
±
0.08 [mm]
C. Washer thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17
±
0.07 [mm]
D. Bushing inside diameter (assembled) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128.06
±
0.1 [mm]
E. Idler shaft diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127.725
±
0.025 [mm]
Diametral clearance (D - E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.35
±
0.1 [mm]
End clearance A - (B + 2C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.6
±
0.3 [mm]