Section 05 TRANSMISSION
Sub-Section 06 (CHAINCASE)
05-06-2
REMOVAL
To remove chaincase proceed as follows.
Remove tuned exhaust pipe and muffler.
WARNING : Never remove exhaust com-
ponents when engine is hot.
8,9,12, Hair Pin, Adjustment Screw and
Chain Tensioner
Remove hair pin. Release drive chain tension by
unscrewing tensioner adjustment screw.
1,2, Chaincase Cover and Screw
Drain oil by removing chaincase cover.
3,4,5,6,13,16,17, Cotter Pin, Nut,
Sprocket, Shim and Drive Chain
Remove cotter pin, nut, washer retaining upper
sprocket and screw retaining lower sprocket. Pull
sprockets and drive chain simultaneously. Re-
move shims.
NOTE : Should countershaft removal be re-
quired, refer to BRAKE 05-05 then look for
Brake disc.
26, Circlip
Remove circlip. Refer to BRAKE 05-05 then lock
for brake disc.
14, Nut
Remove 5 nuts. 3 nuts are behind the lower
sprocket.
23,24,25, Screw, Locking Tab and Nut
Unfold locking tab, unscrew nuts then remove
caliper retaining screws.
21, Drive Axle Holder
Release track tension, use drive axle holder (P / N
529 0072 00).
TYPICAL
1. Drive axle
2. Suspension cross shaft
20, Drive Axle Oil Seal
Pry out from chaincase.
Pull chaincase from drive axle and countershaft.
7, Chaincase
Using two large screwdrivers inserted between
chaincase and frame, pry complete assembly
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 10-03 for gear ratio.
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 0624
00 and P / N 484 0545 00 for binder) gives infor-
mation about calibration according to altitude.
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A01B1FA
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529 0072 00
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