Engine
4
‐
41
Inspect the shift forks
Shift fork follower (1)
Shift fork pawl (2)
Look for scoring, bends, wear or
damage.
Guide bar
Roll the guide bar on a flat surface.
Look for bends.
Do not attempt to straighten a bent
guide bar.
Shift fork movement
on the guide bar.
Look for smooth movement.
If replacement is necessary, replace as a
set
.
Springs
Look for cracks or damage.
Shift drum
Inspect the grooves
Look for scratches, wear or
damage.
High wheel gear and middle
drive gear
Check gear teeth.
Look for discoloration, pitting or
wear.
Mated dogs
Look for rounded edges, cracks or
missing portions.
Gear movement
Look for smooth movement.
Circlips
Look for bends, looseness or
damage.
Summary of Contents for Challenger 500
Page 1: ...SERVICE MANUAL Challenger 500 Challenger 700...
Page 50: ...500 UV Engine Specifications 2 10...
Page 51: ...500 UV Engine Specifications 2 1 1...
Page 52: ...500 UV Engine Specifications 2 12...
Page 53: ...500 UV Engine Specifications 2 13...
Page 209: ...Electrical 6 11 Ignition System Circuit Diagram 1 High tension coil 2 C D I 3 Magneto...
Page 213: ...Electrical 6 15 Electric Starting System...
Page 216: ...Electrical 6 18 Charging System...
Page 218: ...Electrical 6 20 Lighting System...
Page 219: ...Electrical 6 21 Signaling System...
Page 220: ...Electrical 6 22 Cooling System...
Page 221: ...Electrical 6 23 2WD 4WD Selecting System...
Page 244: ...MTD Products Inc Product Training and Education Department FORM NUMBER 769 10856 05 2015...