Subsection XX (CHAINCASE (4-STROKE ENGINES)

CHAINCASE (4-STROKE ENGINES

SERVICE TOOLS
Description Part Number Page
BEARING PULLER/PUSHER ......................................................... 529 036 111 ........................................... 6
BEARING PULLER/PUSHER ......................................................... 529 036 112 ........................................... 6

SERVICE TOOLS – OTHER SUPPLIER

Description Part Number Page
SNAP-ON SEAL PULLER .............................................................. YA105 ........................................... 7

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Subsection XX (CHAINCASE (4-STROKE ENGINES)

NEW

10 N•m
(89 lbf•in)

NEW
48 N•m
(35 lbf•ft)
6 N•m
(53 lbf•in)

10 N•m
(89 lbf•in)
See tightening
23 N•m sequence
(17 lbf•ft)

Hand
On torque
applicable
models

15 N•m
(133 lbf•in) See Accessories

See tightening sequence

NEW = Component must be replaced when removed.

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 Subsection XX (CHAINCASE (4-STROKE ENGINES)

GENERAL
During assembly/installation, use the torque val-
ues and service products as in the exploded view.
Clean threads before applying a threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for
complete procedure.

WARNING
Torque wrench tightening specifications
must be strictly adhered to. mmr2009-131-023_a

Locking devices when removed (e.g.: locking TYPICAL

1. Speed sensor connector
tabs, elastic stop nuts, cotter pin, etc.) must
be replaced with new ones. 6. Remove reverse gear retaining screw.

NOTICE Hoses, cables and locking ties re-

moved during a procedure must be reinstalled
as per factory standards.

PROCEDURES
CHAINCASE
Chaincase Cover Removal
With Mechanical Reverse
Remove the support attached to chaincase. Refer mmr2009-131-025_a

to MECHANICAL REVERSE subsection. TYPICAL

1. Reverse gear retaining screw
With Electronic Reverse
7. Remove lower retaining screw from shifter link
Remove the electronic shift unit. Refer to ELEC- rod.
TRONIC REVERSE subsection.
With Mechanical or Electronic Reverse
1. Apply parking brake.
2. Remove muffler. Refer to EXHAUST SYSTEM
subsection.
3. Remove battery. Refer to CHARGING SYSTEM
subsection.
4. Remove battery rack.
5. Disconnect speed sensor connector.

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TYPICAL
1. Shifter link rod lower retaining screw

8. On applicable models, remove RH side panel

strap from frame.

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Subsection XX (CHAINCASE (4-STROKE ENGINES)

Chaincase Disassembly
1. Apply parking brake.
2. Remove chaincase cover. Refer to CHAIN-
CASE COVER REMOVAL in this subsection.

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1200 4-TEC SHOWN

1. Retaining nut
2. Side panel strap

9. Place a container under vehicle in line with

chaincase drain plug to catch chaincase oil.

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1. Upper sprocket
2. Reverse sprocket
3. Lower sprocket
4. Reverse gear
5. Sliding gear
6. Shift fork

Shift Fork (in Chaincase Cover)

1. Remove spring pins using a punch as shown.
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1. Magnetic check plug

10. Unscrew and remove chaincase cover

screws.

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1. Shift fork

2. Pull out shift rod from chaincase cover.

3. Remove shift fork.
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1. Chaincase cover screws Gears and Sprockets

NOTE: Do not remove tension on drive chain for
11. Pull the bottom of chaincase cover to drain the
the moment.
remaining oil.
1. Remove upper screw that hold sliding gear as-
12. Wait a moment then remove the cover com-
sembly.
pletely.

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 Subsection XX (CHAINCASE (4-STROKE ENGINES)

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UPPER SCREW REMOVAL

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1. Press rod
2. Remove chain tensioner from chaincase. 2. Deep socket
3. Upper sprocket
3. Remove sliding gear assembly, reverse 4. Sliding gear
sprocket and reverse gear simultaneously.
4. Firmly retain upper sprocket with one hand.
5. Remove circlip from coupling shaft.

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Sliding Gear Disassembly mmr2009-131-033_a

1. Circlip
NOTICE Do not use the press to compress
the sliding gear while disassembling. Use 6. Carefully release spring tension.
the press ONLY as a guide to ensure that the
spring tension will be released safely.
1. Install sliding gear assembly on a press.
2. Position a 25 mm (1 in) deep socket on the up-
per sprocket side.
3. Adjust press rod on the socket, do not apply
pressure on the assembly.

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7. Remove upper sprocket and sliding gear from

press.

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Subsection XX (CHAINCASE (4-STROKE ENGINES)

Chain and Lower Sprocket

1. Remove the lower sprocket circlip.

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DRIVE AXLE BEARING SHOWN

1. Snap ring
2. Bearing
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1. Lower sprocket 3. Install the appropriate bearing extractor:

2. Circlip
REQUIRED TOOLS
2. Remove lower sprocket and drive chain simul-
BEARING
taneously. PULLER/PUSHER
Chain Tensioner (P/N 529 036 111)
for countershaft
1. Unscrew lock nut from tensioner adjustment
screw. BEARING
PULLER/PUSHER
2. Remove tensioner adjustment screw from ten- (P/N 529 036 112)
sioner arm. for drive axle
3. Remove tensioner arm from chaincase.
4. Install the extractor/installer tool behind the
bearing.

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1. Lock nut
2. Tensioner adjustment screw 1. Extractor/installer tool
3. Tensioner arm
5. Install the extractor cup over bearing.
Chaincase Bearings
6. Tighten the extractor/installer tool screw to re-
NOTE: This procedure can be applied either for move the bearing.
the countershaft bearing or the drive shaft bear-
ing.
1. Remove the countershaft or the drive axle,
depending which bearing is replaced. Refer to
DRIVE SYSTEM AND BRAKE section.
2. Remove the snap ring securing bearing into
chaincase.

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 Subsection XX (CHAINCASE (4-STROKE ENGINES)

5. Using a 1/4 in drill bit, remove rivet located on

right side of chaincase.

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1. Extractor cup
2. Tighten to remove bearing

7. Using a seal puller such as the SNAP-ON SEAL

PULLER (P/N YA105), remove and discard the oil mmr2009-131-035

seal.
6. Unscrew bolt behind the top of chaincase.

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Chaincase Removal
1. Disassemble chaincase. Refer to CHAINCASE
DISASSEMBLY in this subsection.
2. Remove drive axle. Refer to DRIVE SYSTEM
AND BRAKE subsection.
3. Remove countershaft. Refer to DRIVE SYS-
TEM AND BRAKE subsection.
4. Using a small angle grinder, remove the follow-
ing rivet heads.
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1. Chaincase
2. Retaining bolt
3. RH side frame member
7. Using 2 large pry bars inserted between chain-
case and frame, pry chaincase out of vehicle.
Chaincase Inspection
Chaincase Cover
Inspect cover for cracks or other damages, re-
place if necessary.
Inspect cover front and rear stopper for crack, re-
place if necessary.
Inspect O-ring inside cover is brittle, hard or dam-
aged, replace if necessary.
Shift Fork, Lever and Link Rod
Inspect shift fork for straightness, replace if nec-
essary.
Inspect shift fork wear or other damages, replace
if necessary.
Inspect shift lever for straightness and for rotation
movement, replace if necessary.

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Subsection XX (CHAINCASE (4-STROKE ENGINES)

Inspect link rod for straightness and other dam- Inspect threads of tensioner adjustment screw for
ages, replace if necessary. damages or wear, replace if necessary.
Spring Inspect rubber washer condition, replace if neces-
sary.
Measure spring free length, replace if out of spec-
ification. Bearings
TUNDRA 600 ACE Inspect all bearings for smooth operation:
– If rough or excessive play is detected, replace
SPRING FREE LENGTH
bearing.
50 mm ± 1 mm
Service limit
(1.969 in ± .039 in) Chaincase Installation
To install the chaincase, have the following parts
ALL OTHER 600 ACE/900ACE/1200 4-TEC
in hands:
SPRING FREE LENGTH
PARTS TO INSTALL CHAINCASE
48 mm ± 1 mm
Service limit QTY FASTENERS P/N
(1.89 in ± .039 in)
1 Mounting plate 518 325 816
M6 x 20 hexagonal
3 207 662 034
flanged bolt
8 M6 elastic flanged nut 233 261 434

1. Install mounting plate.

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TYPICAL
A. Free length
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Chain, Gears and Sprockets UNDERNEATH FRAME
1. Mounting plate
Inspect the chain, gears and sprockets for:
– Wear 2. Install chaincase.
– Cracks 3. Install 5 elastic flanged nuts to secure chain-
– Damages teeth case.
– Missing links. NOTE: Unless otherwise noted, bolts and nuts
If a problem is detected: holding the chaincase must be installed loosely
– Replace drive chain and sprockets as an assem- FIRST.
bly. 4. Install 2 flanged bolts and secure with elastic
– Replace upper sprocket and sliding gear as an flanged nuts.
assembly.
– Replace reverse sprocket and reverse gear as
an assembly.
Chain Tensioner
Inspect chain tensioner sliders for wear or other
damages, replace if necessary.

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 Subsection XX (CHAINCASE (4-STROKE ENGINES)

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1. Install bolt here

2. Mounting plate

5. Install a flange bolt to secure chaincase to RH

side member.
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NUT LOCATED OUTSIDE

6. Install bolt behind the top of chaincase.

7. Tighten all nuts to specification as per the fol- mmr2011-103-003_a
lowing sequence.
8. Install countershaft. Refer to DRIVE SYSTEM
TIGHTENING TORQUE
AND BRAKE subsection.
Chaincase retaining nuts 10 N•m (89 lbf•in)
9. Install drive axle. Refer to DRIVE SYSTEM AND
BRAKE subsection.
10. Assemble chaincase. Refer to CHAINCASE
ASSEMBLY in this subsection.
Chaincase Assembly
Chaincase Bearings
NOTE: This procedure can be applied either for
the countershaft bearing or the drive shaft bear-
ing.
1. Install the NEW oil seal on the extractor/installer
tool. Position the lips toward bearing.

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Subsection XX (CHAINCASE (4-STROKE ENGINES)

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mmr2008-044-117_a 1. Bearing
1. Extractor/installer tool 2. Extractor/installer tool
2. Oil seal lips on this side
6. Tighten extractor/installer tool screw to install
2. Install extractor cup inside frame. the bearing.
7. Remove tool.
Chain Tensioner
The installation procedure is the reverse of re-
moval.
Chain and Lower Sprocket
The installation procedure is the reverse of re-
moval, however pay attention to the following.
Install sprocket with its inscription outward.
Sliding Gear
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1. Extractor cup NOTICE Do not use the press to compress

3. Tighten extractor/installer tool screw to install
the oil seal.
4. Install large washer and extractor/installer tool
screw inside frame.
the sliding gear while assembling. Use the
press ONLY as a guide to ensure that the
spring tension will be applied safely.
The installation procedure is the reverse of re-
moval, however pay attention to the following.
Install coupling shaft circlip on the splines side.
Install upper sprocket circlip on a press.

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Step 1: Install splines circlip

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Step 2: Install upper sprocket circlip on a press
1. Large washer 1. Sliding gear
2. Extractor/installer tool screw 2. Upper sprocket

5. In chaincase, install NEW bearing and extrac-

tor/installer tool.

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 Subsection XX (CHAINCASE (4-STROKE ENGINES)

Apply parking brake.

Torque upper screw to specifications.
TIGHTENING TORQUE
Upper screw
(securing the sliding 48 N•m (35 lbf•ft)
gear)

Shift Fork (in Chaincase Cover)

The installation procedure is the reverse of re-
moval, however pay attention to the following.
Position shift fork lever toward the inside.
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Gears and Sprockets

The installation procedure is the reverse of re-
moval, however pay attention to the following.
Assemble reverse sprocket and reverse gear as
per the following illustration.

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1. Shift fork lever

Install spring pins into both holes.

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1. Reverse sprocket
2. Reverse gear

Install sliding gear assembly, reverse sprocket and

reverse gear simultaneously.

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TYPICAL
1. Large hole

Ensure that seal is properly seated on the chain-

case cover.
Chaincase Cover
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Install chaincase cover. Refer to CHAINCASE
Install upper screw that hold sliding gear assem- COVER in this subsection.
bly. (do not tighten for the moment).
Adjust tension on the drive chain. Refer to DRIVE
CHAIN ADJUSTMENT in this subsection.
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Subsection XX (CHAINCASE (4-STROKE ENGINES)

Chaincase Cover Installation
The installation procedure is the reverse of re-
moval, however pay attention to the following.
Ensure cover O-ring is positioned correctly in its
groove.
Ensure that link rod is positioned with the double
reference marks upwards.
Install the shift lever and adjust the shift linkage.
Refer to MECHANICAL REVERSE or ELEC-
TRONIC REVERSE depending on the type of
vehicle.
Install battery and battery rack. Refer to CHARG-
ING SYSTEM subsection.
Install muffler. Refer to EXHAUST SYSTEM sub-
section.
Refill chaincase. Refer to CHAINCASE OIL in PE-
RIODIC MAINTENANCE PROCEDURES subsec-
tion.

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1. Double reference marks

Torque chaincase cover screws in accordance

with the following sequence.

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TIGHTENING TORQUE
CHAINCASE COVER SCREWS
Same chaincase 10 N•m (89 lbf•in)
NEW chaincase 15 N•m (133 lbf•in)

Torque reverse gear retaining screw as per speci-

fication.
TIGHTENING TORQUE
Reverse gear screw 15 N•m (133 lbf•in)

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