Arctic Cat DVX 400 2004, Service Manual

Page: 60 / 153

31
SP223
2. Install the crank balancer shaft.
3. Simultaneously, install the driveshaft and counter-
shaft assemblies making sure the washer is on the
countershaft.
4. Making sure the circlip is in position, install the
reverse idler shaft; then install a washer, bushing,
reverse idler gear, wave washer, and thrust washer.
5. Place each of the three shift forks into its respective
gear or dog (1) (2) (3) as noted during disassembling.
SP224
6. Install the shift cam (4); then install the shift fork
shaft (5) and the reverse lock shaft (6).
SP225

NOTE: Check to be sure that the gears all engage
normally; then shift the transmission into neutral.
7. Verify that the two crankcase half alignment pins (1)
are in place.
SP226

NOTE: Prior to joining crankcase halves, turn the
shift cam to ensure all gears shift properly.
Joining Crankcase Halves
1. Verify that the washer is on the reverse idler shaft;
then apply Three Bond Sealant (p/n 0636-070) to the
mating surfaces. Place the right-side half onto the
left-side half.
SP227
2. Using a plastic mallet, lightly tap the case halves
together until cap screws can be installed.
3. From the left side, install the six case half cap
screws; then tighten only until snug.
SP228

NOTE: Rotate the shafts back and forth to ensure
no binding or sticking occurs.