Service manual
67
Checking Tooth Contact
NOTE: After correcting backlash of the secondary
driven bevel gear, it is necessary to check tooth con-
tact.
1. Remove the secondary driven output shaft assembly
from the left-side crankcase half.
2. Clean the secondary driven bevel gear teeth of old oil
and grease residue.
3. Apply a thin, even coat of a machinist-layout dye to
several teeth of the gear.
4. Install the secondary driven output shaft assembly.
5. Rotate the secondary driven bevel gear several revo-
lutions in both directions.
6. Examine the tooth contact pattern in the dye and
compare the pattern to the illustrations.
ATV-0103
ATV-0105
ATV-0104
Correcting Tooth Contact
NOTE: If tooth contact pattern is comparable to the
correct pattern illustration, no correction is neces-
sary.
If tooth contact pattern is comparable to an incorrect pat-
tern, correct tooth contact according to the following
chart.
NOTE: To correct tooth contact, steps 1 and 2 (with
NOTE) of “Correcting Backlash” must be followed
and the above “Tooth Contact/Shim Correction” chart
must be consulted.
CRANKSHAFT ASSEMBLY
Measuring Connecting Rod
(Small End Inside Diameter)
NOTE: The crankshaft and connecting rod is a
non-serviceable assembly. If any component is out of
specification, the assembly must be replaced.
1. Insert a snap gauge into the upper connecting rod
small end bore; then remove the gauge and measure
it with micrometer.
CC290D
2. Maximum diameter must not exceed specifications.
Measuring Connecting Rod
(Small End Deflection)
1. Place the crankshaft on a set of V-blocks and mount a
dial indicator and base on the surface plate. Position
the indicator contact point against the center of the
connecting rod small end journal.
2. Zero the indicator and push the small end of the con-
necting rod away from the dial indicator.
3. Maximum deflection must not exceed specifications.
Tooth Contact Shim Correction
Contacts at Top Decrease Shim Thickness
Contacts at Root Increase Shim Thickness
CAUTION
After correcting tooth contact, backlash must again be
checked and corrected (if necessary). Continue the cor-
recting backlash/correcting tooth contact procedures
until they are both within tolerance values.