3-33
3
KM623
2. Inspect the shift forks for distortion, discoloration,
or excessive wear.
3. Inspect the shift cam groove and shift cam gear for
excessive wear.
KM624
4. Inspect the shift shaft and gear for excessive wear.
Check that the spring is not broken.
KM683
5. Inspect all gear teeth for chipping, discoloration,
pitting, or excessive wear. Replace as required.
6. Inspect clutch dogs and mating surfaces for chip-
ping, rounding, or excessive wear. Replace as
required.
7. Inspect all bearings, bushings, seals, and shafts for
proper fit, surface mating, or discoloration.
Replace as required.
8. Inspect transmission housing and cover for cracks,
scoring or galling of bearing bores, or case discol-
oration.
9. Inspect the drive and driven bevel gears for chip-
ping, flaking, or excessive wear in the splines.
Replace as required.
KM422
10. Inspect the secondary driven bevel gear housing
for cracks, loose bearings, or signs of discoloration
from heat. Replace as required.
11. Inspect the driven shaft for scoring, discoloration,
or worn splines.
KM421
Assembling
1. Using the appropriate bearing and seal drivers,
install any required bearings and seals in the trans-
mission case and case cover.
KM696
2. Replace any required bearings and seals in the sec-
ondary driven bevel gear shaft case. Apply oil to
all seal lips.
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Summary of Contents for ATV 250 Utility 2009
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