75
CLEANING AND INSPECTING
1. Inspect the sprocket teeth for wear. If they are worn
as shown, replace the engine sprocket, rear sprocket,
and drive chain as a set.
ATV2185
2. Measure the rear axle runout as shown using V
blocks and a dial indicator. If the axle runout exceeds
1.5 mm (0.06 in.), the axle must be replaced.
KM480
3. Inspect the dust seals for wear or damage. If any
defect is found, replace the dust seal.
4. Inspect the axle bearings by rotating them by hand. If
any roughness, binding, or excessive looseness is
found, replace the axle bearings.
NOTE: If the axle bearings are replaced, replace the
dust seals with new ones. Always pack the bearings
with a good quality wheel bearing grease.
Removing Bearings
1. Remove the dust seals using an appropriate seal
removal tool; then using an appropriate driver, drive
the bearings out of the axle housing.
NOTE: Do not reuse bearings after removal.
2. Clean the axle housing and inspect for cracks, elon-
gated holes, and wear in bearing bores.
Installing Bearings
1. Pack the new bearings with a good quality wheel
bearing grease; then install the right bearing first
using an appropriate bearing installer.
2. Install the left bearing; then install new dust seals
and lightly coat the lips with grease.
INSTALLING
1. Slide the axle into the axle housing from the right
side; then apply multipurpose grease to all splined
areas of the axle.
2. Install the sprocket and sprocket hub on the axle and
secure with the nuts; then tighten securely. Install the
drive chain.
KM477
3. On the left side, install the brake disc assembly; then
install the brake caliper and secure with the two cap
screws. Tighten to 24 ft-lb.
TR236
NOTE: It is necessary to calculate the torque value
using the following formula due to the offset of the
special tool used to tighten the axle nuts.
T: Torque wrench reading to be calculated
Ts: Specified torque value (86 ft-lb)
Ls: Tool offset length (center to center)
L: Length of torque wrench (handle pivot to headcen-
ter)
L x Ts
= T
L + Ls
