ATV REAR DRIVE SERVICE TOOLS

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Page 1

Section 07 DRIVE SYSTEM

Subsection 03 (REAR DRIVE)

REAR DRIVE

SERVICE TOOLS

Description Part Number Page

BACKLASH MEASUREMENT TOOL............................................. 529 035 665 ......................................... 620

CV BOOT CLAMP PLIER .............................................................. 529 036 120 ......................................... 616

CV JOINT EXTRACTOR................................................................. 529 036 005 ......................................... 617

SPANNER SOCKET ....................................................................... 529 035 649 ......................................... 623

SERVICE PRODUCTS

Description Part Number Page

LOCTITE 277 ................................................................................. 293 800 073 ......................................... 625

LOCTITE 648 (GREEN) .................................................................. 413 711 400 ......................................... 619

XPS SYNTHETIC GREASE................................................. ............ 293 550 010 .................................615, 618

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Section 07 DRIVE SYSTEM

Subsection 03 (REAR DRIVE)

MODELS WITH 500 ENGINE

XPS Synthetic

grease

MAX models

NEW

Short models

205 ± 15 N•m

(151 ± 11 lbf•ft)

NEW

XPS

Synthetic

grease

XPS Synthetic

grease

XPS Synthetic

grease

NEW

XPS Synthetic

grease

Hi-temp bearing grease

NLGI-2 or equivalent

XPS Synthetic

grease

NEW

90 ± 5 N•m

(66 ± 4 lbf•ft)

NEW

Loctite

648

75 ± 5 N•m

(55 ± 4 lbf•ft)

Loctite

648

NEW

= Component must be replaced when removed.

NEW

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XPS Synthetic

grease

NEW

205 ± 15 N•m

(151 ± 11 lbf•ft)

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MODELS WITH 450 ENGINE

XPS Synthetic

grease

MAX models

Section 07 DRIVE SYSTEM

Subsection 03 (REAR DRIVE)

NEW

Short models

205 ± 15 N•m

(151 ± 11 lbf•ft)

NEW

XPS

Synthetic

grease

XPS Synthetic

grease

NEW

XPS Synthetic

grease

Hi-temp bearing grease

NLGI-2 or equivalent

Loctite

648

XPS Synthetic

grease

NEW

90 ± 5 N•m

(66 ± 4 lbf•ft)

NEW

Loctite

648

75 ± 5 N•m

(55 ± 4 lbf•ft)

NEW

= Component must be replaced when removed.

NEW

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XPS Synthetic

grease

NEW

205 ± 15 N•m

(151 ± 11 lbf•ft)

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Section 07 DRIVE SYSTEM

Subsection 03 (REAR DRIVE)

NEW

32 ± 3 N•m

(24 ± 2 lbf•ft)

XPS synthetic

grease

NEW

For preload adjustment

NEW

For backlash

adjustment

22.5 ± 2.5 N•m (17 ± 2 lbf•ft)

NEW

180 ± 15 N•m

(133 ± 11 lbf•ft)

LH threads

Loctite 277

NEW

XPS synthetic grease

= Component must be replaced when removed.

NEW

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NEW

5 ± 1 N•m

(44 ± 9 lbf•in)

XPS synthetic

grease

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Section 07 DRIVE SYSTEM

Subsection 03 (REAR DRIVE)

PROCEDURES

WHEEL HUB

Wheel Hub Remo

Lift and support vehicle. Remove the wheel. Remove the foll

– Caliper mounting bolts (if applicable), refer to

BRAKES

– Hub cap – Cotter pin – Wheel hub nut – Belleville washer.

subsection

val

owing parts:

Wheel Hub Inspection

Remove disk from RH wheel hub as necessary. Check wheel hub for cracks or other damages. Check inner splines for wear or other damages. If any damage is detected on wheel hub, replace

it with a new one.

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Wheel Hub Installation

The installation is the reverse of the removal procedure. However, pay attention to the following:

Apply drive shaft splines.

Install Belleville washer with its convex side outward.

XPS SYNTHETIC GREASE (P/N 293 550 010) on

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1. Caliper

2. Remove bolts

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TYPICAL

1. Co tter pin

2. Wheel hub nut

3. Belleville washer

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1. Wheel h

2. Washer — Convex side here

3. Nut

Remove wheel hub.

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Section 07 DRIVE SYSTEM

Subsection 03 (REAR DRIVE)

TIGHTENING TOR

Wheel hub nut

QUE

205N•m ± 15N•m

(151 lbf•ft ± 1

1lbf•ft)

NOTE: If required, tighten castellated nut further to align grooves with drive shaft hole.

Install a NEW

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DRIVE SHA

cotter pin.

Drive Shaft Inspection

Inspect the condition of boots. If there is any damage or evidence of leaking lubricant, replace them. Refer to

DRIVE SHAFT BOOT

Check shaft splines. Replace drive shaft if necessary.

Check dust shield on drive shaft end. Replace if necessary.

Drive Shaft Installation

The installation is the reverse of the removal procedure. However, pay attention to the following:

Install a NEW stop ring.

Drive Shaft Removal

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TYPICAL

1. Drive shafts

Lift and support vehicle. Remove the wheel hub. See procedure in this

subsection. Remove trailing arm. Refer to

SION

Strongly pull drive shaft out of final drive.

REAR SUSPEN-

V07H0AA

TYPICAL

1. NEW stop ri

After drive shaft insertion in rear final drive, validate if properly locked.

DRIVE SHAFT BOOT

Drive Shaft Boot Removal

Remove the drive shaft from vehicle. See procedure in this subsection.

Remove dr ing tool:

CV BOOT CLAMP PLIER

Dislodge the large boot end. Separate the joint from the shaft. Two procedures

can be done.

Without the Special Tool

Clamp joint housing in a vise. Align shaft with joint. Pull hard on shaft to remove from joint. Remove boot from drive shaft.

ive shaft boot clamps using the follow-

TOOL

(P/N 529 036 120)

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Section 07 DRIVE SYSTEM

Subsection 03 (REAR DRIVE)

Remove and discard the circlip. A new one is included in the boot kit.

With the Special Tool

Place drive shaft in vice with the joint downward. Install the

CV JOINT EXTRACTOR (P/N 529 036 005)

on bearing.

529036005

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TYPICAL — CV JOINT SHOWN

1. Joint extractor tool

With an hammer, hit on the tool to separate joint from shaft.

When joint and shaft are separated, remove boot from drive shaft.

Remove and discard the circlip. A new one is included in the boot kit.

Remove drive shaft boot.

PROPELLER SHAFT

Propeller Shaft Removal

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TYPICAL

1. Propeller shaft

1. Lift and support rear end of vehicle.

2. Remove wheels. Refer to

TIRES

subsection.

3. Drain oil from rear final drive. Refer to

ODIC MAINTENANCE PROCEDURES

4. Detach brake master cylinder from frame. Refer to

BRAKES

subsection.

WHEELS AND

PERI-

Drive Shaft Boot Installation

The installation is the reverse of the removal procedure. However, pay attention to the following:

Pack bearing area with grease (included with the new boot kit).

NOTE: Do not use any other grease.

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1. Remove retaining screws

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Section 07 DRIVE SYSTEM

Subsection 03 (REAR DRIVE)

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1. Master cylinder moved apart

5. From RH side of vehicle, remove propeller shaft screw from gearbox output shaft.

NOTE: Heat screw to break the threadlocker bond prior to removal.

7. Remove rear final drive retaining bolts. Refer to

REAR FINAL DRIVE

in this subsection.

8. Remove bolts from rear retaining plate. Refer

REAR FINAL DRIVE

in this subsection.

9. Move the rear final drive rearward t o allow dislodging the propeller shaft.

10. Dislodge the propeller shaft from the gearbox.

11. Remove the propeller shaft.

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AL — RH SIDE OF VEHICLE

TYPIC

1. Remove screw

6. From LH side of vehicle, remove propeller shaft screw from rear final drive yoke.

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1. Pull out propeller shaft

Propell

er Shaft Inspection

Inspect if propeller s haft is not bent or twisted. Check propeller shaft splines for wear or damage. Check if

or britt

propeller shaft bellow is cracked, pierced

le.

Propeller Shaft Installation

The inst cedure.

Apply splines.

allation is the reverse of the removal pro-

However, pay attention to the following:

XPS SYNTHETIC GREASE (P/N 293 550 010) to

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LH SIDE OF VEHICLE

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Section 07 DRIVE SYSTEM

Subsection 03 (REAR DRIVE)

PARTS TO R Q U E

75 N•m ± 5 N•m

Propeller shaft screw

(rear final dr

Propeller shaft screw

(gearbox si

ive side)

de)

LOCTITE 648 (GREEN)

Refill rear final drive. Refer to

NANCE PROCEDURES

subsection.

(55lbf•ft± 4l

(P/N 413 711 4

75 N•m ± 5 N•m

(55 lbf•ft ± 4

(P/N 413 711

PERIODIC MAINTE-

bf•ft)

00)

lbf•ft)

400)

PROPELLER SHAFT U-JOINTS

Propeller Shaft U-Joint Removal

Remove internal snap ring from bearing caps.

Support U-joint in vice and drive inner yoke down to remove remaining bearing caps.

Remove U-joint cross.

Propeller Shaft U-Joint Installation

Install a NEW U-joint in inner yoke. NOTE: Position propeller shaft U-joint as shown

for proper grease fitting location.

V01H10A

Install bearing caps. Use a vise to push bearing caps.

V01H0YA

1. Snap ring

Support inner yoke in vice and drive other yoke downwithasofthammer.

V01H11A

Using a suitable pusher, fully seat bearing cap on one side.

V01H0ZA

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Section 07 DRIVE SYSTEM

Subsection 03 (REAR DRIVE)

V01H12A

Install snap ring. Complete installation for the other bearing caps. Grease U-joint. Refer to

NANCE PROCEDURES

PERIODIC MAINTE-

subsection.

REAR FINAL DRIVE

Rear Final Drive Removal

Drain oil. Refer to

PROCEDURES

Lift and support vehicle. Support rear bottom end of frame. Remove drive shafts. See procedure in this sub-

section. Remove rear propeller shaft screw from the rear

final drive yoke. Refer to this subsection.

Remove rear final drive screws (5x).

PERIODIC MAINTENANCE

subsection.

PROPELLER SHAFT

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Unplug the vent hose from final drive.

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1. Pull out

Remove

the final drive.

Rear Final Drive Inspection (Assem

Manually turn rear final drive gear; it should turn smoothly. Repair if necessary.

Check if oil seals are brittle, hard or damaged. Replace if necessary.

bled)

Backla

Using a dial indicator and the

SUREMENT TOOL (P/N 529 035 665)

sh Inspection

BACKLASH MEA-

, measure the

backlash. Place the backlash measurement tool at the end

of pinion gear.

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From ce and sc

nter of tool bolt, measure 25.4 mm (1 in)

ribe a mark on the tab.

Remove bolts from rear retaining plate.

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Section 07 DRIVE SYSTEM

Subsection 03 (REAR DRIVE)

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1. Tab of backlash measurement tool

2. Mark on tab A. 25.4 mm (1 in)

Position the dial indicator tip against the tab at a 90° angle and right on the previously scribed mark.

Gently, move the tool tab back and forth. Note the backlash result.

BACKLASH ADJUS

BACKLASH

MEASUREMENT

Below 0.1 mm (.004 in)

Above 0.35 mm (.014 in)

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1. Backlash shim

TMENT GUIDELINE

WHAT TO DO

Add shim(s) and recheck backlash

Remove shim(s) and recheck bac klas h

6-023-016

vmr200

Rotate pinion gear 1/2 turn and recheck backlash. Note the result.

Rotate pinion gear 1 turn and recheck backlash.

BACKLASH SPECIFICATION

0.1 mm (.004 in) to 0.35 mm (.014 in)

If backlash is out of specification, split final drive housing and adjust shim thickness as per following guideline.

Preload Inspection

Screw the propeller shaft screw in pinion gear.

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vmr20

Using a needle torque wrench, measure the preload.

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Section 07 DRIVE SYSTEM

Subsection 03 (REAR DRIVE)

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PRELOAD SPECIFICATION

0.06 N•m (.5 lbf•in)to0.50N•m(4lbf•in)

If preload is out of specification, split final drive housing and adjust shim thickness as per following guideline.

PRELOAD GUIDELINE

PRELOAD

MEASUREM

ENT

Below 0.06 N•m

in)

(.5 lbf•

Above 0.50 N•m

(4 lbf•i

WHAT TO DO

Add shim(s) and recheck preload

Remove shim(s) and recheck

preload

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Split final drive housings. NOTE: Be careful to keep track of shims on ring

gear.

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1. Backla

2. Preload shim

3. Ring gear

Extrac

sh shim

t ring gear out of half housing.

Pinion Gear

Remove and discard oil seal.

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oad shim

1. Prel

Rear Final Drive Disassembly

Gear

Ring

Remove the final drive housing screws.

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Unscrew the pinion nut. Use the SPANNER

SOCKET (P/N 529 035 649)

529035649

Section 07 DRIVE SYSTEM

Subsection 03 (REAR DRIVE)

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1. O-ring

2. Ball bearing

3. Pinion gear shim

4. Pinion gear

The pinion gear and bearing can be easily removed using the following suggested tool:

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NOTE: The pinion nut is left hand threaded. Unscrew by turning clockwise.

Remove the bearing along with the pinion gear. Be careful to keep track of shims. Discard bearing.

PART QTY

Pipe: 83 mm (3-1/4 in) diameter x 127 mm (5 in)

Threaded rod: M10 x 1.25 x 178 mm (7 in)

M10 x 1.25 nut 3

Flat bar

Remove and discard the needle bearing.

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Rear Final Drive Assembly

Adjustment is required when any of the following part is changed.

– Pinion gear – Ring gear – Housing.

As a preliminary setup, install shims according to the following table.

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Section 07 DRIVE SYSTEM

Subsection 03 (REAR DRIVE)

RECOMMENDED SH

PINION GEAR

BACKLASH

PRELOAD

See procedure for pinion gear

(as a p re lim in ary adju stm e nt)

IM THICKNESS

shim thickness

0.5 mm (.02 in)

Procedure for pinion gear shim thickness:

1. Remove the old pinion gear and install the new one without the ball bearing. The new pinion will be located at the "zero" location.

2. Measure the face of the g

distance "A" between outside surear case and the shim surface of

pinion.

3. Measure the distance "B" between outside surface of the gear case and the bearing shoulder of the gear case.

4. The shim thicknesss will be "A-B-0.53 mm (.021 in)".

5. Select the the thick

good combination of shim to match

ness calculated on step 4.

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1. Backlash side

2. Preload side

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1. Backlash shim

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1. Preload shim

Prior to finalizing assembly, proceed in this order:

– Temporarily assemble final drive using recom-

mended torques. – Do not apply thread locker product. – Do not install a new pinion nut.

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Section 07 DRIVE SYSTEM

Subsection 03 (REAR DRIVE)

– Check backlash. – Check preload.

Ring Gear

The installation is the reverse of the removal procedure. However, pay attention to the following:

Check condition of seal. Replace if damaged.

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Install N

EW bearings.

Install the shim(s) then a NEW ball bearing. install a NEW O-ring. Apply

LOCTITE 277 (P/N 293 800 073) to pinion nut.

Install and tighten the p inion nut as per specification.

TIGHTENING TORQUE

180N•m ±15N•m

Pinion nut

(LH THREADS)

Lubricate an

dinstallaNEW oil seal.

(133 lbf•ft ± 11 lbf•ft)

LOCTITE 277 (P/N 293

800 073)

Rear Final Drive Installation

The installa cedure. How

Install the lowest rear final drive retaining screws first.

Install all screws and nuts prior to tighten. Tighten nut

Final drive retaining nuts

tion is the reverse of the removal pro-

ever, pay attention to the following:

s to specification.

TIGHTENING TORQUE

90 N•m ± 5 N•m

(66 lbf•ft ± 4 lbf•ft)

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Tighten final drive housing screws as per specification.

ENING TORQUE

TIGHT

Final drive housing

scre

on Gear

Pini

32 N•m ± 3 N•m

bf•ft ± 2 lbf•ft)

(24 l

The installation is the reverse of the removal procedure. However, pay attention to the following:

Install a NEW needle bearing.

Refill the final drive with recommended oil. Refer to

PERIODIC MAINTENANCE PROCEDURES

subsection.

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