Arctic Cat 650 Twin2004, Service Manual

Page: 140 / 210

6-12
Shimming Procedure/Shim
Selection
502-119A
1. Press bearings into bores by outer ring to hard
contact with seat.
2. Note the following shim selections (shims are
nominally 1.5 mm/0.060 in. thick):
A. Pinion Gear Sub-Assembly - add the value
(A) on the gear case housing with 1.5 mm
(0.060 in.); then subtract the value on the
10-tooth pinion gear. This will give you the
proper shim thickness.
B. Cover Side - add the value (B) on the gear
case housing to the value (C) on the gear case
cover; then add 1.5 mm (0.060 in.). This will
give you the proper shim thickness.
C. Gear Case Side - install a 1.3-1.4 mm
(0.050-0.055 in.) shim and tighten the bolts
to 3.5-4.3 kg-m (25-31 ft-lb). Verify backlash
to be within a range of 0.28-0.38 mm
(0.011-0.015 in.) and end-play to be within a
range of 0.10-0.20 mm (0.004-0.008 in.). If
not within specification range, reselect shim
until backlash specification range can be
verified.
738-268A
3. Apply molybdenum disulfide grease to all oil seal
lips.
4. Prelubricate journal on pinion assembly with SAE
80W-90 hypoid gear lubricant prior to pressing
assembly into gear case housing.
5. Tighten lock collar to 16.6 kg-m (120 ft-lb) and
deform/lock edge approximately 1.5 mm (0.060
in.) into lower oil channel.
Assembling Pinion Gear
1. Place the shim ( with the chamfer side toward the
inside) onto the pinion shaft; then install the
bearing onto the pinion shaft. Install the pinion
shaft collar.
CC881
CC882