Removal
Drain the final drive oil (page 3-17).
Remove the rear wheel (page 14-3).
Support the swingarm and remove the left shock absorber lower mounting bolt and release the shock from the gear case.
Remove the gear case mounting nuts, then remove the final gear case.
Drive shaft removal/disassembly
Separate the drive shaft from the gear case by gently turning the drive gear shaft and pulling.
Remove the spring, oil seal and stopper ring from the drive shaft.
Check the splines of the drive shaft for damage or wear.
If the splines of the drive shaft are damaged, check the universal joint splines also.
Universal joint removal
Remove the swingarm (page 14-12) and remove the universal joint from the swingarm.
Check that the universal joint moves smoothly without binding or noise.
Check the splines for wear or damage.
Final drive inspection
Turn the pinion joint and check that the ring gear turns smoothly and quietly without binding.
If the gears do not turn smoothly or quietly, the bearings and/or gears may be damaged or faulty.
They must be checked after disassembly; replace them if necessary.
Backlash inspection
Perform the backlash inspection and tooth contact pattern check (page 12-10) whenever you replace the gear set, bearings or gear case. The extension lines from the gear engagement surfaces should intersect at one point.
Remove the oil filler cap.
Place the final gear assembly into a jig or vise with soft jaws.
Set a horizontal type dial indicator on the ring gear, through the oil filler hole.
Hold the pinion gear spline with the pinion holder plate and collars.
Tools:
- Pinion holder plate 07924-ME40010
- Collar set "С" 07924-ME40020
Turn the ring gear back and forth to read the backlash.
Standard: 0.05-0.15 mm (0.002-0.006 in).
Service limit: 0.30 mm (0.012 in).
Remove the dial indicator. Turn the ring gear 120° and measure the backlash. Repeat this procedure once more.
Compare the difference between the three measurements.
Backlash difference between measurements:
Service limit: 0.10 mm (0.004 in).
If the difference in measurements exceeds the limit, it indicates that the bearing is not installed squarely. Inspect the bearings and install if necessary.
If backlash is excessive, replace the ring gear shim with a thicker one.
If the backlash is too small, replace the ring gear shim with a thinner one.
Ring gear shims:
- A: 1.82 mm (0.072 in)
- B: 1.88 mm (0.074 in)
- C: 1.94 mm (0.076 in)
- D: 2.00 mm (0.079 in) — Standard
- E: 2.06 mm (0.081 in)
- F: 2.12 mm (0.083 in)
- G: 2.18 mm (0.086 in)
- H: 2.24 mm (0.088 in)
- I: 2.30 mm (0.091 in)