Yamaha MM600D, Manual

Page: 225 / 282

CHAINCASE, AND FRONT AXLE
219
7. Install the drive sprocket nut (A, Figure 14) and
washer.
8.
Install the spring Figure 13) and spring seat
9. Apply Loctite 242 (blue) to the driven sprocket bolt
(A, Figure
then install the bolt and washer.
10. Have an assistant apply the hydraulic brake. Tighten
the drive sprocket nut (A, Figure 14) to 60
(43
Tighten the driven socket bolt (A, Figure 13) to 48
(35
11. Install the chain tensioner Figure 14).
Install the spring (Figure 23) into the countergear,
then install the reverse drive gear Figure 24). Make
sure the spring fits into the hole in the reverse drive gear.
13. Install the washer (A, Figure 24) against the reverse
drive gear.
14. Install the gasket and chaincase cover onto the
chaincase. The shift fork ends must fit into the groove on
reverse driven gear (Figure 25). Make sure the rubber
gasket fits on the chaincase properly.
15. Install the chainease cover bolts and tighten them to
24
(1 7
j.
16. Apply Loctite 242 (blue) to the reverse axle shaft
bolt, then install the bolt and washer (Figure 26). Tighten
the bolt to 10
(88
17. Reconnect the shift lever rod.
18. Fill the chaincase with oil as described in Chapter
Three.
19. Adjust chain tension as described in Chapter Three.
CHAINCASE
Removal
Refer to Figure 1 or Figure 8 when performing this
procedure.
Open the shroud.
2. Remove the hydraulic brake caliper as described in
Chapter Eleven.
3.
Remove the parking brake caliper as described in
Chapter Eleven.
4A. On and
models remove the drive chain, sprockets and gears as de-
scribed in this chapter.
4B. On all other models remove the drive chain and
sprockets as described in this chapter.
5. Remove the chaincase (Figure
6. Remove the collars and O-rings on the jackshaft (Fig-
ure 28) and front axle (Figure 29).
Inspection
Remove the oil seals (Figure 30).
2. Inspect the bearings (A, Figure Ifbearing removal
is necessary, remove the snap ring (B) and press or drive
out the bearing. When installing a new bearing, apply
force only to the outer race of the bearing.
3. Install new oil seals so the open side is toward the bear-
ing.
Installation
1. Install an O-ring into the groove in each collar (Figure
32).
2. Lightly lubricate the O-rings and instal1 the collars
onto the and front axle (Figure 28 and Figure
29).
NOTE
Because of the weight of the track on the
front axle, it may be to position the
in order to install the retaining bolts.
NOTE
I f installed, the chaincase drain bolt
must
engage the hole in the tunnel before the
chaincase will fit properly.
3. Lubricate the lips of the oil seals, then install the
chainease (Figure
27). Tighten the chainease bolts to 48
(35
4A. On and
models install the drive chain, sprockets and gears as de-
scribed in this chapter.
4B. On all other models install the drive chain and sprock-
ets as described in this chapter.
5. Install the hydraulic brake caliper as described in
Chapter Eleven.
6.
Install the parking brake caliper as described. in Chap-
ter Eleven.
JACKSHAFT
Removal
Refer to Figure 33.
1. Remove the secondary sheave as described in Chapter Ten.
2. Remove the brake disc as described in Chapter
Eleven.
3. Remove the washer (A, Figure 34) and snap ring
NOTE
bearing lock collar setscrews
have
a
head. Do not attempt to
turn
the
using an Allen wrench or it will
damage the screw head.