ATVSV3D.PDF

Click Here to Go Back

Fig. 3-398

Fig. 3-400

CC197D

CC166D

AT THIS POINT

9. Remove the driven gear from the crank balancer.

Account for a key.

To service the driveshaft and/or countershaft,

see Servicing Center Crankcase Components in

this sub-section.

Fig. 3-401

NOTE: For efficiency, if the driveshaft and/or

countershaft are not being serviced, it is preferable

to leave them assembled. The technician should use

discretion and sound judgment.

8. Remove the front shaft (4x4) and rear shaft

assemblies. Account for the bearing C-ring.

Fig. 3-399

CC167D

Fig. 3-402

CC110D

NOTE: Note the alignment marks on the crank

balancer driven gear and balancer drive gear to aid

in assembly.

CC165D

AT THIS POINT

To service the driven gear, see Servicing Center

Crankcase Components in this sub-section.

NOTE: For efficiency, if the driven gear is not

being serviced, it is preferable to leave it assembled.

The technician should use discretion and sound

judgment.

10. Remove the crank balancer.

3-81

Fig. 3-403

Fig. 3-405

CC168D

CC482D

NOTE: When removing the crank balancer

assembly, rotate the crankshaft counterweight away

from the crank balancer assembly counterweight.

Assembling

Crankcase Half

11. Using the Crankcase Separator/Crankshaft

Remover (p/n 0444-009), push the crankshaft

assembly out of the crankcase.

Fig. 3-404

NOTE: For ease of assembly, install components

on the left-side crankcase half.

NOTE: If the output shaft was removed, make sure

that the proper shim is installed.

1. To install the output shaft, place the shaft into

position with proper shims, slide the gear onto the

shaft, and secure with a new nut tightened to 10

kg-m (72 ft-lb).

Fig. 3-406

CC115D

AT THIS POINT

To service crankshaft assembly, see Servicing

Center Crankcase Components in this

sub-section.

! CAUTION

CC117D

Do not remove the remaining output shaft

assembly unless absolutely necessary. If the

shaft is removed, the shaft nut must be replaced

with a new one and the shaft must be

re-shimmed.

12. To remove the output shaft, remove the nut, slide

the gear off the shaft (account for a shim or shims),

and drive the shaft out with a plastic mallet (account

for a shim or shims).

3-82

Fig. 3-407

Fig. 3-410

CC116D

CC165D

2. Using the Crankshaft Installer (p/n 0444-018),

install the crankshaft.

Fig. 3-411

Fig. 3-408

CC167D

Fig. 3-412

CC151D

3. Install the crank balancer.

Fig. 3-409

CC166D

5. Place the bearing C-ring into position in the

crankcase; then install the front shaft (4x4) and rear

shaft assemblies.

CC168D

4. With the key in position, slide the driven gear onto

the crank balancer making sure the timing marks

are aligned.

! CAUTION

The bearing pins must be positioned into the

crankcase.

3-83

Fig. 3-413

Fig. 3-416

CC110D

CC231D

6. Simultaneously, install the driveshaft and

countershaft assemblies making sure the washer is

on the countershaft.

8. Place each of the four shift forks into its respective

gear or dog as noted during disassembling; then

install the gear shift cam.

Fig. 3-414

Fig. 3-417

CC197D

CC107D

7. Install the reverse idle shaft with circlip making

sure the oil hole in the shaft is facing downward;

then install a washer, bushing, reverse idle gear, and

a washer.

Fig. 3-418

Fig. 3-415

CC106D

9. Engage the four forks to the gear shift cam; then

install the reverse shift cam and spacer.

CC229D

3-84

Fig. 3-419

Joining Crankcase

Halves

1. Place the O-ring in the left-side crankcase half and

verify that the shim washer is on the idler shaft; then

apply Three Bond Sealant (p/n 0636-070) to the

mating surfaces. Place the right-side half onto the

left-side half.

Fig. 3-422

CC105D

Fig. 3-420

CC101D

Fig. 3-423

CC103D

10. Install the two gear shift fork shafts; then verify that

the two crankcase half alignment pins are in place.

Fig. 3-421

CC102D

Fig. 3-424

CC104D

NOTE: Prior to joining crankcase halves, turn the

shift cam to ensure all gears shift properly.

CC234D

2. Using a plastic mallet, lightly tap the case halves

together until cap screws can be installed.

3-85

Plik z chomika:

Inne pliki z tego folderu:

Inne foldery tego chomika: