ODES UTV Desertcross 1000cc-3, Maintenance Manual

Page: 149 / 230

3. ENGINE
3-
103
Gearbox Inspection
Always verify for the fol1owing when
inspecting gearbox components:
- Gear teeth damage
- Worn or scoured bearing surfaces
- Rounded engagement dogs and slots
- Worn shift fork engagement groove
- Worn splines on shafts and shifting sleeves.
Bearings
Check if ball bearings turn freely and smoothly.
Check all bearings, bearing points, tooth flanks
and taper grooves.
Free Pinions
NOTE: Always replace snap rings and use
special pliers to install them.
Check free pinions for wear.
TYPICAL
1. Micrometer
2. Free pinion
DIAMETER FREE PINION
NEW
29.000 mm
to29.013mm
(1.1417in
to1.1422in)
SERVICE
LIMIT 29.015mm(1.1423in)
Shifting Sleeves
Check shifting sleeves for worn inner splines
and rounded or damaged engagement dogs.
TYPICAL
1. Inner splines
2. Engagement dogs
Measure the width of shift fork engagement
groove.
TYPICAL
1. Shifting sleeve
A. Width of shift fork engagement groove
WIDTH 0F SHIFT FORK
ENGAGEMENT GROOVE
NEW
5.30 mm to5.40
mm
(.209in to.213in)
SERVICE LIMIT
5.50mm(.217in)
Shafts
Check bearing pin of reverse intermediate gear
for wear.