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4-7-4. Gear shift mechanism removal
01. remove the gear shift pedal (1) Fig. 4-103
02. remove the gear shift spindle (2) and washer (3) Fig. 4-103
03. remove the stopper (1) and spring (2) Fig. 4-104
04, remove the gear shift cam bolt (3.) Fig. 4-204
05. remove the gear shift cam and set pin
4-7-5. Gear shift inspection and installation
- The installation should follow the reverse order o£ removal.
01. check gear shift cam stopper for any wear or damage -- replace Fig. 4-105
02 . check gear shift plate for any wear or deformation -- replace Fig. 4-106
03. check gear shift angles for any wear or damage -- replace Fig. 4-107
04. install the gear shift cam stopper (1) and spring (2) Fig. 4-108
05. tighten the 6 mm lock bolt * torque: 0.8 - 1.2 kg-m
06. install the set pin (1) into the transmission drum hole Fig. 4-109
07. install gear shift cam, aligning the pin hole in gear shift car. with set pin. after the gear shift cam is on
position, put the stopper in the gear shift cam groove and tighter. stopper bolt.
08. rotate transmission drum to make sure the stopper operation.
09. tighten the bolt
* torque: 0.8 - 1.2 kg-m
10. install the gear shift spindle and washer. Be sure the return spring aligns with the crankcase tab.
11. install the outer clutch and thrust washer. Be sure thrust washer chamfered side facing up.
12. install the clutch
13. staffer the clutch friction disks and clutch plates and put them on the clutch center.
14. install the clutch center together with the well-arranged friction disks and plates into the outer clutch.
15. install the circlip. The circlip chamfered side racing up
16. install the tension spring and clutch lifter.
17. install the washer to the bolts and tighten the 4 bolts x torque: 0.8 - 1.2 kg-m
18. install the clutch lifter guide pin and oil filter rotor
19. install the washer, the make OUTSIDE facing up and lock nut
* torque: 4.0 - 5.0 kg-m
20. install the oil filter rotor cover
21. check: the gasket for any wear or damage -- replace
22. put the 3 oil filter rotor cover screws - torque: 0.3 - 0.4 kg-m
4-7-6. R. crankcase cover installation
- The installation should follow the reverse order of removal by installing the dowel, pins, gasket and install
the right crankcase cover and tighten the mounting bolts
* torque: 0.8 - 1.2 kg-r.
Summary of Contents for ATV DXR 200
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Page 154: ...153 6 2 IGNITION SYSTEM BRIEFING 01 AC generator 03 Ignition coil 02 C D I 04 plug cap ...
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