Section 04 TRANSMISSION
Sub-Section 07 (CHAINCASE)
04-07-6
REMOVAL
To remove chaincase proceed as follows.
Remove tuned exhaust pipe and muffler.
WARNING : Never remove exhaust com-
ponents when engine is hot.
Remove hair pin
no. 18
. Release drive chain ten-
sion by unscrewing tensioner adjustment screw.
Drain oil by removing chaincase cover
no. 2
.
3,4,5,6,13,16,17, Cotter Pin, Nut,
Sprocket, Shim and Drive Chain
Remove cotter pin
no. 3
, nut
no. 4
, washer
no. 27
retaining upper sprocket
no. 5
and screw
no. 15
retaining lower sprocket
no. 16
. Pull sprockets
and drive chain simultaneously. Remove shims
nos. 6
and
17
.
NOTE :
Should countershaft removal be re-
quired, refer to BRAKE 04-06 then look for
Brake disc
.
Remove 5 nuts
no. 14
. Three nuts are behind the
lower sprocket.
Unfold locking tab
no. 24
, unscrew nuts
no. 25
then remove caliper retaining screws
no. 23
.
Release track tension, use drive axle holder
no.
21
(P / N 529 0072 00).
TYPICAL
1. Drive axle
2. Suspension cross shaft
Pry out drive axle oil seal
no. 20
from chaincase.
Pull chaincase from drive axle and countershaft.
Using 2 large screwdrivers inserted between
chaincase
no. 7
and frame, pry complete assem-
bly from vehicle.
INSPECTION
Visually inspect the chain for cracked, damaged or
missing links. Check for worn or defective bear-
ings, sprockets and chain tensioner components.
WARNING : If chain deflection is greater
than 38 mm (1.5 in) (without chain ten-
sioner), replace chain and check condition of
sprockets.
GEAR RATIO MODIFICATION
For particular applications, the number of teeth of
the sprockets can be increased or decreased on
lower and upper sprockets.
Refer to TECHNICAL DATA 09-03 for gear ratios.
CAUTION : Gear ratio modifications
should only be performed by experienced
mechanics since they can greatly affect vehicle
performance.
NOTE :
For high altitude regions, the High
Altitude Technical Booklet (P / N 484 0648
00 and P / N 484 0545 00 for binder) gives infor-
mation about calibration according to altitude.
INSTALLATION
Reverse removal procedure and pay attention to
the following. Replace oil seals, gaskets and O-
rings.
Refer to DRIVE AXLE 06-04 for drive axle axial
play adjustment.
11, Oil Seal
Clean chaincase bore with Loctite Safety Solvent
(P / N 413 708200) then apply Loctite 609 to oil
seal mounting surface (outside).
Using an appropriate pusher, press the oil seal
into chaincase hub. Oil seal must fit flush with the
chaincase edge.
NOTE :
Should installation procedure for
countershaft be required, refer to BRAKE 04-
06 then look for
Brake disc and Countershaft
bearing adjustment.
5,16, Sprockets
Position the sprockets with the writing facing the
chaincase cover.
;
A01B1FA
1
529 0072 00
2
;
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