Arctic Cat 650 Twin2004, Service Manual

Page: 141 / 210

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6
CC883
2. Place the pinion assembly in a bearing puller; then
install the bearing using a press.
CC884
3. Install the pinion gear assembly into the housing.
Using the 48 mm Internal Hex Socket
(p/n 0444-104), secure the pinion gear assembly
with the existing nut. Tighten to 17.5 kg-m (125
ft-lb).

NOTE: On a front differential, the nut has
right-hand threads. On a rear gear case, the nut
has left-hand threads.
CC890
4. Place a punch on the edge of the nut in the oil
gallery area; then using a hammer, stake the nut to
ensure that the nut will remain securely tightened.
CC891
5. Install the shift fork shaft w/spring into the gear
housing making sure the shaft O-ring is positioned
to the inside.
CC892
6. Install the shift fork assembly making sure the fork
leg is facing upward. Apply a small amount of oil
to the gasket; then install the gasket.
CC893
7. Place the input shaft assembly onto the gear
housing; then secure with the existing cap screws.
Tighten to 2.9-3.5 kg-m (21-25 ft-lb).

NOTE: If a new gear housing is being installed,
tighten the cap screws to 3.5-4.3 kg-m (25-31 ft-lb).