95
NOTE
PROBLEMS SHOOTING
<Q-A> Excessive engine noise?
- worn main shaft journal bearing, or worn crankshaft pin bearing
- worn transmission system bearing
<Q-A> Transmission gear tripping?
- worn gear teeth, or bent transmission fork
- damaged gear shift cam stopper
<Q-A> Hard shifting?
- clutch improperly adjusted
- bent or damaged transmission fork, or bent gear shift spindle
- damaged transmission drum grooves
4-8-1. Crankcase removal
01. cylinder head removal -- refer to pare 4-4
02. cylinder/piston removal -- refer to part 4-5
03. starter motor/generator/L crankcase/.. -- refer 10 pare 4-6
04. clutch/gear shift mechanism -- refer to part: 4-7
05. remove the 8 L crankcase bolts Fig. 4-110
06. use the plastic hammer to sperate L and R crankcase halves, be sure do not use the driver pry the
crankcase that will damage the mating surfaces Fig. 4-222
07. remove the gasket (1) and dowel pins (2), be sure don’t lose the gear shift spindle washer Fig. 4-222
4-8-2. Transmission system removal and inspection
01. remove the transmission fork shaft and transmission forks (2) Fig. 4-113, 4-114
02. remove the transmission drum (1) Fig. 4-115
03. inspect each transmission fork for bending or damage Fig. 4-116
04. measure each transmission fork claw thickness.
* service limit: less than 4.43mm -- replace
05. measure each transmission fork shaft hole I.D. (a) Fig. 4-116
* service limit: more than 12.058mm -- replace
06. check the transmission fork shaft for bending or damage
07. measure each transmission fork shaft O.D.(a) Fig. 4-117
* service limit: less than 11.936mm -- replace
08. check the transmission drum for scratches or poor lubrication
09 - check the transmission drum groove for damage
10. check the bearing for excessive free play
11. measure the transmission drum O.D. Fig. 4-117
* service limit
L: less than 19.926mm(a) -- replace
R: less than 20.919mm(b) -- replace
12. check the transmission drum and fork shaft holes in the L and R crankcase halves for wear or damage.
Содержание ATV DXR 200
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