Ski-Doo Formula S 1998, Shop Manual

Page: 199 / 338

Section 05 TRANSMISSION
Subsection 08 (GEARBOX)
05-08-3
Install drive axle with track then bearing and circlip
in chaincase bore. Install spacer
no. 38 with its
large outer diameter against sprocket, 44-tooth
sprocket
no. 34 , coupling shaft no. 33 , cap no. 40
and screw no. 31 .
Place a 25 cm (10-inch) rule against sprockets.
Maximum allowable offset is 1 mm (.040 in).
a. If upper sprocket is too far in, possible causes
are:
1. Countershaft bearing on driven pulley side
may be too far in. To check, pull out bearing
using countershaft bearing remover (P/N 529
0301 00) then recheck sprocket alignment.
Use bearing installer (P/N 529 0302 00) to re-
position bearing. Bearing housing (triangle)
must be against frame without preload.
2. Add shim(s) between chaincase and frame
and reposition bearing on driven pulley side
accordingly.
b. If upper sprocket is too far out, check:
If there are too many shims between chaincase
and frame. Remove shims accordingly and re-
position bearing on driven pulley side.
Press needle bearing in 44-tooth sprocket. As-
semble drive pins
no. 35 and their spring no. 36
on 44-tooth sprocket. Tighten nut no. 37 to 5 N•m
(44 lbf• in ) in a criss-cross sequence.
Insert spring pin no. 21 in reverse axle up to in-
side diameter. Press needle bearing in 19-tooth
sprocket. Install ring
no. 24 and 19-tooth sprocket
on reverse axle.
1. Reverse axle ass’y
2. Sliding gear ass’y
Install shim no. 13 , 22-tooth sprocket (drive)
no. 12 and washer no. 11 then tighten castellated
nut no. 10 and conical spring washer. Secure with
a new cotter pin.
Install chain no. 28 , 44-tooth sprocket no. 34 and
its spacer no. 38 . Spacer’s large outer diameter
must be against sprocket. Insert coupling shaft
no. 32 in 44-tooth sprocket.
Install needle bearing no. 15 (wider one) in re-
verse gear no. 18 .
Install reverse axle no. 20 (assembly) making sure
to properly position spring pin in housing slot. In-
stall alignment rod
no. 19 , reverse gear no. 18
and spacer no. 24 . Drive sprocket hole and driven
gear hole must be aligned to insert alignment rod.
Mount chain tensioner (assembly) to adjustment
screw already fixed to gearbox. Assemble fork
no. 17 to axle using spring pins no. 16 . Apply
grease on O-rings.
6, Cover
Join cover (assembly) to housing. Make sure fork
tabs are behind sliding sprocket thrust washer.
1. Fork tabs
2. Thrust washer
A15D1WA
1
2
-
CAUTION
Gearbox cover must completely lay against
housing.
2
A15D1VB
1