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Section 05 TRANSMISSIONSubsection 01 (TABLE OF CONTENTS)

MMR2002_109_05_01ATOC.FM 05-01-1

TABLE OF CONTENTS 0DRIVE BELT............................................................................................................................ 05-02-1

APPLICATION CHART ....................................................................................................... 05-02-1

INSPECTION ...................................................................................................................... 05-02-1CHECKING NEUTRAL FUNCTION.................................................................................... 05-02-1ROTATION DIRECTION ..................................................................................................... 05-02-1DRIVE BELT HEIGHT MEASUREMENT AND ADJUSTMENT......................................... 05-02-2DRIVE BELT DEFLECTION MEASUREMENT (reference only) ....................................... 05-02-3

DRIVE PULLEY....................................................................................................................... 05-03-1

BOMBARDIER LITE ........................................................................................................... 05-03-1

GENERAL ........................................................................................................................... 05-03-2REMOVAL........................................................................................................................... 05-03-2DISASSEMBLY................................................................................................................... 05-03-3CLEANING ......................................................................................................................... 05-03-3INSPECTION ...................................................................................................................... 05-03-3ASSEMBLY......................................................................................................................... 05-03-3INSTALLATION .................................................................................................................. 05-03-4TRA..................................................................................................................................... 05-03-5

GENERAL ........................................................................................................................... 05-03-6REMOVAL........................................................................................................................... 05-03-6DISASSEMBLY................................................................................................................... 05-03-6CLEANING ......................................................................................................................... 05-03-8INSPECTION ...................................................................................................................... 05-03-8ASSEMBLY......................................................................................................................... 05-03-9INSTALLATION .................................................................................................................. 05-03-11DRIVE PULLEY ADJUSTMENT......................................................................................... 05-03-12

DRIVEN PULLEY.................................................................................................................... 05-04-1

LPV27 ................................................................................................................................. 05-04-1

DISASSEMBLY................................................................................................................... 05-04-2INSPECTION ...................................................................................................................... 05-04-2ASSEMBLY......................................................................................................................... 05-04-3INSTALLATION .................................................................................................................. 05-04-3ADJUSTMENT................................................................................................................... 05-04-4FORMULA .......................................................................................................................... 05-04-5

REMOVAL........................................................................................................................... 05-04-6DISASSEMBLY................................................................................................................... 05-04-6CLEANING ......................................................................................................................... 05-04-6INSPECTION ...................................................................................................................... 05-04-6ASSEMBLY......................................................................................................................... 05-04-7INSTALLATION .................................................................................................................. 05-04-7ADJUSTMENT................................................................................................................... 05-04-7

Section 05 TRANSMISSIONSubsection 01 (TABLE OF CONTENTS)

05-01-2 MMR2002_109_05_01ATOC.FM

HPV27 ................................................................................................................................. 05-04-9

REMOVAL ........................................................................................................................... 05-04-10DISASSEMBLY ................................................................................................................... 05-04-10CLEANING .......................................................................................................................... 05-04-10INSPECTION....................................................................................................................... 05-04-10ASSEMBLY ......................................................................................................................... 05-04-11INSTALLATION................................................................................................................... 05-04-11ADJUSTMENT.................................................................................................................... 05-04-11

PULLEY DISTANCE AND ALIGNMENT ................................................................................ 05-05-1

GENERAL............................................................................................................................ 05-05-1GENERAL PROCEDURE..................................................................................................... 05-05-1PULLEY ALIGNMENT AND DISTANCE SPECIFICATIONS CHART ................................. 05-05-2

BRAKE..................................................................................................................................... 05-06-1

MECHANICAL BRAKE........................................................................................................ 05-06-1

HYDRAULIC BRAKE........................................................................................................... 05-06-2

BRAKE PADS REPLACEMENT........................................................................................... 05-06-4REMOVAL ........................................................................................................................... 05-06-5DISASSEMBLY ................................................................................................................... 05-06-6CLEANING .......................................................................................................................... 05-06-6INSPECTION....................................................................................................................... 05-06-6ASSEMBLY ......................................................................................................................... 05-06-6INSTALLATION................................................................................................................... 05-06-7ADJUSTMENT.................................................................................................................... 05-06-8BLEEDING........................................................................................................................... 05-06-9

CHAINCASE............................................................................................................................ 05-07-1

REMOVAL AND DISASSEMBLY ....................................................................................... 05-07-2INSPECTION....................................................................................................................... 05-07-2GEAR RATIO MODIFICATION............................................................................................ 05-07-2INSTALLATION AND ASSEMBLY ..................................................................................... 05-07-3DRIVE CHAIN ADJUSTMENT............................................................................................ 05-07-3ADJUSTMENT.................................................................................................................... 05-07-4

DRIVE CHAIN ......................................................................................................................... 05-08-1

SILENT CHAIN.................................................................................................................... 05-08-1

Section 05 TRANSMISSIONSubsection 02 (DRIVE BELT)

MMR2002_086_05_02A.FM 05-02-1

DRIVE BELT 0APPLICATION CHART

INSPECTIONInspect belt for cracks, fraying or abnormal wear(uneven wear, wear on one side, missing cogs,cracked fabric). If abnormal wear is noted, proba-ble cause could be pulley misalignment, excessiveRPM with frozen track, fast starts without warm-up period, burred or rusty sheave, oil on belt ordistorted spare belt.Check the drive belt width. Replace the drive beltif width is less than the minimum width recom-mended (see table above).

CHECKING NEUTRAL FUNCTION

Apply parking brake. Vehicle must be on theground and on a plane level surface. No oneshould be in front of vehicle.Attach vehicle tether cord to your clothing. Standaside of vehicle then, start engine.

Release parking brake. Vehicle must not creep whenengine is idling. Otherwise, make sure that:– idle speed is as specified– proper belt is installed– pulley center-to-center is as specified– belt deflection is as specified.

ROTATION DIRECTIONThe maximum drive belt life span is obtained whenthe drive belt is installed as shown. This will ensurethat correct direction of rotation is respected.

CORRECT

MODEL PART NUMBER WIDTH (new)± 0.25 mm (.010 in)

MINIMUM WIDTH (wear limit)mm (in)

All fan cooled models except Summit 500 F 415 060 600 34.70 (1.366) 32.30 (1.272)

Summit 500 F 417 300 066 35.10 (1.382) 33.00 (1.299)

All 493 and 593 engine equipped models

except Summit 600414 860 700 35.30 (1.390) 32.30 (1.272)

All 693 and 793 engine equipped models and

Summit 600417 300 127 36.35 (1.431) 33.35 (1.313)

� WARNING

Always check neutral function when servicing.

� WARNING

Do not sit on vehicle.

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05-02-2 MMR2002_086_05_02A.FM

INCORRECT

NOTE: For used drive belt, mark and reinstall in thesame position.

DRIVE BELT HEIGHT MEASUREMENT AND ADJUSTMENT

MeasurementBefore checking the belt height, ensure that agood-condition proper belt (refer to the ApplicationChart) is installed.Adjust pulley distance and alignment. Refer toPULLEY DISTANCE AND ALIGNMENT.To obtain maximum vehicle performance, the beltheight must be adjusted according to specifica-tions shown in the accompanying chart.

1. Flush

AdjustmentBefore adjusting the belt height, ensure that agood-condition proper belt (refer to the ApplicationChart) is installed.Adjust pulley distance according to specification,refer to PULLEY DISTANCE AND ALIGNMENT.

Models Equipped with Formula Type Driven Pulley

Adjust drive belt height using Allen screws, asshown.To lower belt in driven pulley: turn Allen screwsclockwise.To raise belt in driven pulley: turn Allen screwscounterclockwise.NOTE: Turn Allen screws 1/4 turn at a time, thenrotate driven pulley to allow drive belt to settle inpulley. Check height, repeat as required.

MODEL BELT HEIGHT

All models Top edge of drive belt cord should beflush with driven pulley edge

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MMR2002_086_05_02A.FM 05-02-3

TYPICAL1. Allen screws with jam nuts

Allen screws must be restrained while tighteningjam nut to prevent throwing adjustment out. Usedrive belt tension adjuster (P/N 529 008 700).

TYPICAL

Models Equipped with HPV27 Type Driven Pulley

Loosen screws and turn adjustment ring accord-ingly. Retighten screws.

DRIVE BELT DEFLECTION MEASUREMENT (reference only)NOTE: The drive belt deflection measurementmust be performed each time a new drive belt isinstalled.

NOTE: To obtain an accurate drive belt deflectionmeasurement, it is suggested to allow a break-inperiod of 50 km (30 m.).Before checking the belt deflection, ensure vehi-cle has the proper belt (refer to the ApplicationChart).Adjust pulley distance and alignment. Refer toPULLEY DISTANCE AND ALIGNMENT.To obtain maximum vehicle performance, the belttension must be adjusted according to specifica-tions shown in the accompanying chart.

† FOR REFERENCE ONLY

To Check TensionPosition a reference rule on drive belt.

Wooden Stick and Spring Scale Method

1. Mark specified deflection

Using spring scale and stick, apply specified forceon drive belt halfway between pulleys as shown.

1. Force2. Read deflection here3. Reference rule

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MODEL DEFLECTION†

mm (in)FORCEkg (lb)

All models 32 ± 5 (1.260 ± .197) 11.5 (25)

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05-02-4 MMR2002_086_05_02A.FM

Or use the belt tension tester (P/N 414 348 200).

1. Lower O-ring2. Upper O-ring3. Force (read down)4. Deflection (read up)

1. Slide lower O-ring of deflection scale to speci-fied measure.

2. Slide upper O-ring to 0 (zero) on the force scale.3. Apply pressure until lower O-ring is flush with

edge of rule and read force on the upper scaleat top edge of O-ring.

1. Upper O-ring — force2. Force3. Lower O-ring — deflection4. Reference rule5. Deflection

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Section 05 TRANSMISSIONSubsection 03 (DRIVE PULLEY)

MMR2002_087_05_03A.FM 05-03-1

DRIVE PULLEY 0BOMBARDIER LITENOTE: This is a lubrication free drive pulley.

377 Engine ZX Series

1

2

3

5

6 78

9

11

128 N•m(95 lbf•ft)

95 N•m(70 lbf•ft)

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05-03-2 MMR2002_087_05_03A.FM

GENERALSome drive pulley components (return spring, cali-bration disk) can be changed to improve vehicleperformance in high altitude regions. A service bul-letin will give information about calibration accord-ing to altitude.CAUTION: Such modifications should only beperformed by experience mechanics since theycan greatly affect vehicle performance.

REMOVALNOTE: If disassembling drive pulley, first straight-en tab washer no. 7 then untighten nut no. 8.

Use holder (P/N 529 027 600).Remove retaining screw no. 9.

TYPICAL

Insert drive pulley puller (P/N 529 031 400) thenremove drive pulley.

TYPICAL

� WARNING

Any drive pulley repairs must be performed byan authorized Bombardier snowmobile dealer.Sub-component installation and assembly tol-erances require strict adherence to proceduresdetailed.

� WARNING

Never use an impact wrench to remove or in-stall the drive pulley.

� WARNING

The drive pulley assembly is a precisely bal-anced unit. Never replace parts with usedparts from another drive pulley assembly.

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MMR2002_087_05_03A.FM 05-03-3

DISASSEMBLYUnscrew nut. Remove tab washer.Check for alignment marks for proper indexing atreassembly.

1. Alignment marks

Identify blocks no. 1 and their respective positivepositions for reassembly.

1. Identify

2, Cap, Washer and DiskThese are calibration parts. Refer to TECHNICALDATA.Install spring cover tool (P/N 529 027 300) withpuller (P/N 529 031 400) on spring cover.

1. Puller tool2. Spring cover tool

Screw puller (hand tight) to hold spring cover andremove screws holding spring cover.Slowly unscrew puller to release spring pressure.Remove spring cover no. 5, spring and washerno. 11.

CLEANINGClean pulley faces and shaft with fine steel wooland clean dry cloth. Clean sliding half bushing withclean dry cloth.

INSPECTIONCheck sliding half for excessive lateral play andfixed half shaft for scratches. Replace as required.

ASSEMBLYInstall circlip no. 11 then washer no. 10.Make sure to install blocks at their original positionand with their curved end toward governor cup.See following illustration.Tighten nut no. 8 to 128 N•m (95 lbf•ft).

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05-03-4 MMR2002_087_05_03A.FM

INSTALLATIONTorque screw to 80 to 100 N•m (59 to 74 lbf•ft).Install drive belt and belt guard.Raise and block the rear of the vehicle and supportit with a mechanical stand.

Accelerate the vehicle at low speed (maximum30 km/h (20 MPH)) and apply the brake, repeat5 times.Retorque screw to 90 to 100 N•m (66 to 74 lbf•ft).

� WARNING

Ensure that the track is free of particles whichcould be thrown out while track is rotating.Keep hands, tools, feet and clothing clear oftrack. Ensure nobody is standing near thevehicle.

� WARNING

After 10 hours of operation the transmissionsystem of the vehicle must be inspected toensure the retaining screw is properly torqued.


MMR2002_087_05_03A.FM 05-03-5

TRAGrand Touring Fan 500, MX Z Fan 500, Summit Fan 500, Legend Fan 500 and All Liquid Cooled ZX Series Models

NOTE: This is a lubrication free drive pulley.

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05-03-6 MMR2002_087_05_03A.FM

GENERALSome drive pulley components (return spring,ramp) can be changed to improve vehicle perfor-mance in high altitude regions. A service bulletinwill give information about calibration according toaltitude.CAUTION: Such modifications should only beperformed by experienced mechanics sincethey can greatly affect vehicle performance. Ver-ify spring specifications before installation. Donot only refer to the spring color code.NOTE: TRA drive pulley stands for Total RangeAdjustable drive pulley.

REMOVAL

30,31, Conical Spring Washer and ScrewUse holder (P/N 529 006 400).

TYPICAL1. Retaining screw 2. Insert in any slot

Remove retaining screw.To remove drive pulley ass’y and/or fixed half fromengine, use puller (P/N 529 007 900) for 503 engineequipped models and puller (P/N 529 022 400) forliquid cooled models.CAUTION: These pulleys have metric threads.Do not use imperial threads puller. Always tight-en puller by hand to ensure that the drive pulleyhas the same type of threads (metric vs imperi-al) prior to fully tightening.

To Remove Drive Pulley Ass’y:Retain drive pulley with clutch holder.Install puller in pulley shaft then tighten.

DISASSEMBLY

1,2, Screw and Ring GearCAUTION: Retaining screws must be heated be-fore disassembly. Do not exceed 150°C (300°F).

5,6, Fixed and Sliding HalfCAUTION: Do not tap on governor cup.Screw puller into fixed half shaft about 13 mm (1/2 in).Raise drive pulley and hold it by the sliding half whileknocking on puller head to disengage fixed half.

TYPICAL1. Puller2. Holding sliding half

NOTE: No components marking is required be-fore disassembling this drive pulley since it hasfactory mark and arrows as indexing reference.

� WARNING

Any drive pulley repairs must be performed byan authorized Bombardier snowmobile dealer.Sub-component installation and assembly tol-erances require strict adherence to proceduresdetailed.

� WARNING

Never use any type of impact wrench at drivepulley removal and installation.

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MMR2002_087_05_03A.FM 05-03-7

32, Cushion DriveCAUTION: Do not disassemble cushion drive.Governor cup and cushion drive are factory bal-anced as an assembly.

25,29, Slider Shoe and Governor CupCarefully lift governor cup until slider shoes comeat their highest position into guides.Hold a slider shoe set then carefully lift its housingand remove slider shoes. Proceed the same way forother housings lifting one at a time.

1. Hold slider shoes2. Lift one housing at a time

NOTE: To ease disassembly, forks (P/N 529 005 500)should be used to hold slider shoes prior to removinggovernor cup.

19, Spring Cover Ass’yIt is pushed by clutch spring pressure.

Use spring compressor (P/N 529 035 524).Install support guide.

1. Support guide

Install sliding half then a second support guide. Thesesupport guides will prevent bushing damages.

1. Support guide

Remove 3 Allen screws retaining spring cover thenunscrew compressor.

� WARNING

Clutch spring is very strong. Never attempt toremove spring cover without the recommend-ed tools.

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05-03-8 MMR2002_087_05_03A.FM

CLEANING

5,6, Fixed and Sliding HalfClean pulley faces and shaft with fine steel wooland dry cloth.

5, Fixed Half and Crankshaft EndParts must be at room temperature before clean-ing.Using a paper towel with cleaning solvent, cleancrankshaft tapered end and the taper inside thefixed half of the drive pulley, crankshaft threadsand retaining screw threads.

CAUTION: Avoid contact between cleaner andcrankshaft seal because damage may occur.Remove all hardened oil deposits that have bakedon crankshaft and pulley tapered surfaces withcoarse or medium steel wool and/or sand paperno. 600.CAUTION: Do not use any other type of abrasive.Reclean mounting surfaces with paper towel andcleaning solvent.Wipe off the mounting surfaces with a clean, drypaper towel.CAUTION: Mounting surfaces must be free ofany oil, cleaner or towel residue.

7,20, BushingOnly use petrol base cleaner when cleaning bush-ings.CAUTION: Do not use acetone to clean bushing.

INSPECTIONDrive pulley should be inspected annually.

16,17, Thrust Washer and RollerCheck roller for roundness of external diameter.Check thrust washer for thickness wear. Replaceas required.CAUTION: Ensure rollers are in good condition.Replace as required.

9,12, Fitting Bolt Ass’y and Flanged BushingCheck for wear, replace as required.

24,25, O-Ring and Slider ShoeCheck if O-rings are cracked, cut or crushed. Re-place as required.Check slider shoes for wear. Replace if groove is notapparent on top.

5,29, Fixed Half and Governor CupInspect splines and free play between both parts.Maximum free play is 0.5 mm (.020 in) measuredat calibration screw radius. Replace if required.

7,20, Sliding Half and Spring Cover BushingVisually inspect coating. Replace if worn.

Sliding Half Bushing ReplacementThis bushing is not replacable. If worn out, replacesliding half ass’y.

Spring Cover Bushing ReplacementUnder normal use there is no need to replace thisbushing.Mount compressor (P/N 529 035 524) in a vise.Use tools (P/N 529 031 300 and 529 031 200) toremove old bushing.

CAUTION: Bushing must be bonded with retain-ing compound.

� WARNING

This procedure must be performed in a well-ventilated area.

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529 031 200


MMR2002_087_05_03A.FM 05-03-9

Apply retaining compound Loctite 609 outside ofbushing then press it down to counterbore fromoutside end.CAUTION: Insert bushing from sliding half side(inner side) of spring cover.

ASSEMBLYNOTE: This drive pulley is lubrication free. Do notlubricate any component.

1,2,3, Screw, Ring Gear and Loctite 271Apply Loctite 271 (P/N 413 702 900) on threads andthen torque to 27 N•m (20 lbf•ft).

26,27,28, Calibration Screw, Washer and Locking NutWhen installing calibration screw, make sure to in-stall washer as shown.

1. Washer

Torque locking nut to 10 N•m (89 lbf•in).

15, PinAlways use the same type of pin as originally in-stalled when servicing. Different types have differ-ent weights for calibration purpose. Refer to TECH-NICAL DATA.

21,22,23, Screw, Dowel Tube and RampInsert dowel tube from chamfered side. Makesure ramp is centered on dowel tube.

1. Chamfered side

Position dowel tube split at the illustrated angle.

1. Equal distance

Torque screws to 10 N•m (89 lbf•in).

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05-03-10 MMR2002_087_05_03A.FM

9,11,13,14, Screw, Lever Ass’y, Nut and Cotter PinAlways install lever assemblies so that cotter pinsare on the shown side. Besides install cotter pinhead on top when lever is sat at bottom of slidinghalf. Bend cotter pin ends to sit perfectly againstlever.

1. Head on top2. All on the same side

CAUTION: Lever assemblies must be installed sothat cotter pins are on the same side.Torque nuts to 12 N•m (106 lbf•in).CAUTION: Lever ass’y and rollers must moveeasily after installation.

33, Guard

Some Models Only

Install guard with its reinforcements in line with le-vers.

1. Reinforcements

5,6,18,19, Fixed Half, Sliding Half, Spring, Spring Cover and ScrewTo install spring cover, use spring compressor(P/N 529 035 524).Assemble fixed and sliding halves. Note that fixedhalves have different cone angle. Match cone an-gle with crankshaft.Lift sliding half against spring cover and align springcover arrow with sliding half mark.

1. Align

Install and torque screws to 13 N•m (115 lbf•in).

� WARNING

Whenever replacing centrifugal levers, alwaysreplace all 3 at the same time. Otherwise, drivepulley misbalancing will occur because of le-vers difference.

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MMR2002_087_05_03A.FM 05-03-11

6,25,29, Sliding Half, Slider Shoe and Governor CupTo install governor cup, use following tool:

Insert spring and slider shoes into governor cup sothat groove in each slider shoe is vertical to prop-erly slide in guides.CAUTION: Make sure O-rings are installed onslider shoes and that grooves are positionedvertically.Install fork (P/N 529 005 500) into slider shoe groovesto maintain them for governor cup installation. Pro-ceed on 3 set of slider shoes.

Make sure to align governor cup arrow with slidinghalf and fixed half mark.NOTE: If fixed half has no mark, align governorcup mark with segment no. 1 of inner half. Seg-ments are identified on engine side.

1. Align

Carefully slide governor cup into sliding half. Alignmark of governor cup with mark of fixed half.Remove forks and push governor cup so that itssplines engage with fixed half shaft splines.CAUTION: Make sure splines of both parts arefully engaged.

INSTALLATION

Clean mounting surfaces as described in CLEAN-ING above.

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529 005 500 � WARNING

Do not apply anti-seize or any lubricant oncrankshaft and drive pulley tapers.

� WARNING

Never use any type of impact wrench at drivepulley removal and installation.

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05-03-12 MMR2002_087_05_03A.FM

Drive Pulley Ass’yThe following installation procedure must be strict-ly adhered.Install drive pulley on crankshaft extension.Install a new conical spring washer with its con-cave side towards drive pulley then install screw.

Use holder. See removal procedure.Torque screw to 80 to 100 N•m (59 to 74 lbf•ft).Install drive belt and guard.Raise and block the rear of the vehicle and supportit with a mechanical stand.

Accelerate the vehicle at low speed (maximum30 km/h (20 MPH)) and apply the brake, repeat5 times.Retorque screw to 90 to 100 N•m (66 to 74 lbf•ft).

DRIVE PULLEY ADJUSTMENTThe drive pulley is factory calibrated to transmitmaximum engine power at a predefined RPM. Fac-tors such as ambient temperature, altitude or sur-face condition may vary this critical engine RPMthus affecting snowmobile efficiency.This adjustable drive pulley allows setting maxi-mum engine RPM in the vehicle to maintain max-imum power.Calibration screws should be adjusted so that actu-al maximum engine RPM in vehicle matches withthe maximum horsepower RPM given in TECHNI-CAL DATA.

NOTE: Use precision digital tachometer for engineRPM adjustment.NOTE: The adjustment has an effect on high RPMonly.To adjust, modify ramp end position by turning cal-ibration screws.

26,28,29, Calibration Screw, Locking Nut and Governor CupCalibration screw has a notch on top of its head.

1. Notch

Governor cup has 6 positions numbered 2 to 6.Note that in position 1 there is no stamped num-ber (due to its location on casting).See TECHNICAL DATA for original setting.

1. Position 1 (not numbered)

Each number modifies maximum engine RPM byabout 200 RPM.Lower numbers decrease engine RPM in steps of200 RPM and higher numbers increase it in stepsof 200 RPM.

� WARNING

Never substitute conical spring washer and/orscrew with jobber ones. Always use Bombardiergenuine parts for this particular case.

� WARNING

Ensure that the track is free of particles whichcould be thrown out while track is rotating. Keephands, tools, feet and clothing clear of track. En-sure nobody is standing near the vehicle.

� WARNING

After 10 hours of operation the transmissionsystem of the vehicle must be inspected to en-sure the retaining screw is properly torqued.

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MMR2002_087_05_03A.FM 05-03-13

Example:Calibration screw is set at position 3 and is changedto position 5. So maximum engine RPM is increasedby about 400 RPM.

To Adjust:Just loosen locking nut enough to pull calibrationscrew partially out and adjust to desired position.Do not completely remove the locking nut. Torquelocking nuts to 10 N•m (89 lbf•in).CAUTION: Do not completely remove calibrationscrew otherwise its inside washer will fall off.CAUTION: Always adjust all 3 calibration screwsand make sure they are all set at the same number.

1. Loosen just enough to permit rotating of calibration screw

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Section 05 TRANSMISSIONSubsection 04 (DRIVEN PULLEY)

MMR2002_088_05_04A.FM 05-04-1

DRIVEN PULLEY 0LPV27ZX Series Fan Cooled

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05-04-2 MMR2002_088_05_04A.FM

DISASSEMBLYUse spring compressor (P/N 529 035 524).

TYPICAL

Remove half keys no. 3 and spacer no. 4 to disas-semble the outer cam and the 2 pulley halves.

INSPECTIONReplace bushing(s) if worn more than specified.

10,11, Slider ShoeBlack slider shoe = forward.Red slider shoe = reverse.Check cam slider shoes for wear. Replace wheninside edge thickness of cam slider shoe slopebase is worn to 1 mm (.039 in) or less.

1. Measure thickness of slope base here2. Sliding pulley side 3. Slope base

Bushing ReplacementLarge BushingRemove Allen screws if applicable. Heat to breakLoctite bond.Install support plate included in tool (P/N 529 031100) inside sliding half.Place extractor (P/N 529 035 575) below bushing.

TYPICAL1. Support plate2. Extractor

Mount screw head of new puller (P/N 529 035 524)in a vise.Turn pulley half by hand to extract old bushing.Before bushing installation, file sliding half bore toremove burrs from crimping areas.Coat bushing outside diameter with Loctite 609(P/N 413 703 100). Place new bushing on slidinghalf and slightly tap to engage squarely the bush-ing in the sliding.

� WARNING

Driven pulley cam is spring loaded, use abovementioned tool.

DRIVEN PULLEY BUSHING WEAR LIMITmm (in)

Small bushing 38.30 (1.508)

Large bushing 108.2 (4.260)

529 035 524

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MMR2002_088_05_04A.FM 05-04-3

ASSEMBLY

10,11, Cam Slider ShoeWhen replacing slider shoes, always install a newset (3 shoes) to maintain equal pressure on the cam.Install slider shoes as per following photo. Redslider shoes are being used for reverse and blackones for forward.

1. BLACK slider shoe2. RED slider shoe

Assemble driven pulley components by reversingthe disassembly procedure.

5,6,7, Cam, Guard and SpringMake sure to install proper cam. Refer to TECHNI-CAL DATA.Cam angle is identified on cam.

Position guard no. 6 in cam no. 5 then insert springin adjusting hole no. 3 (mid-hole) into outer cam.Compress outer cam using spring compressor(P/N 529 035 524).Install spacer no. 4 then secure outer cam withhalf keys no. 3, as shown in the next photo.CAUTION: Ensure that half keys are properly in-serted into shaft groove and that spacer recessis facing half keys.

1. Half keys inserted into shaft groove2. Spacer recess facing half keys

INSTALLATION

1, CountershaftCAUTION: Always apply anti-seize lubricant (P/N413 701 000) on the countershaft before final pul-ley installation.

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05-04-4 MMR2002_088_05_04A.FM

Make sure that spacer no. 2 is on countershaft be-fore installing driven pulley. Note also that washershoulder is facing driven pulley.

TYPICAL1. Spacer2. Shoulder on this side

Should installation procedure be required, refer toBRAKE then look for Brake Disc and Counter-shaft Bearing Adjustment.Reinstall the pulley on the countershaft by revers-ing the removal procedure.

14, Pulley Retaining ScrewTorque to 25 N•m (18 lbf•ft).

ADJUSTMENT

Pulley Alignment and Drive Belt DeflectionRefer to PULLEY DISTANCE AND ALIGNMENTand DRIVE BELT to perform adjustments.CAUTION: Drive belt and pulley adjustmentsmust always be checked whenever pulleyshave been removed, replaced or disassembled.

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REMOVALRemove guard and drive belt from vehicle.Remove cap screw no. 12 and shouldered washerno. 11 then pull the driven pulley from the coun-tershaft.Note shouldered washer position for reinstallation.Take care not to loose spacer no. 2.

TYPICAL1. Spacer2. Shoulder on this side

1, Countershaft Should countershaft no. 1 removal be required,refer to BRAKE then look for Countershaft andBrake Disc Removal.


Remove snap ring no. 3 and washer no. 4 to dis-assemble the cam and the 2 pulley halves.

CLEANING

9,10, Large Bushing and Small BushingDuring break-in period (about 10 hours of use),bushing teflon moves toward cam or shaft sur-face. A teflon over teflon running condition occurs,leading to low friction. So it is normal to see grayteflon deposit on cam or shaft. Do not remove thatdeposit, it is not dust.When a dust deposit has to be removed from thecam or the shaft, use dry cloth to avoid removingtransferred teflon.

Pulley Half CleaningUse Pulley Flange Cleaner (P/N 413 711 809).

INSPECTION

9,10, BushingsCheck for cracks, scratch and for free movementwhen assembled to fixed half.Using a dial bore gauge measure bushing diame-ter. Measuring point must be at least 5 mm (1/4 in)from bushing edge.

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MMR2002_088_05_04A.FM 05-04-7

Replace bushing(s) if worn more than specified.

6, Slider ShoeCheck cam slider shoes for wear. Replace wheninside edge thickness of cam slider shoe slopebase is worn to 1 mm (.039 in) or less.


ASSEMBLY

6, Cam Slider ShoeWhen replacing slider shoes, always install a newset (3 shoes) to maintain equal pressure on the cam.Assemble driven pulley components by reversingthe disassembly procedure.

5, CamCoat cam interior with anti-seize lubricant.

INSTALLATION

1, CountershaftCAUTION: Always apply anti-seize lubricant (P/N413 701 000) on the countershaft before finalpulley installation.

Should installation procedure be required, refer toBRAKE then look for Brake Disc and CountershaftBearing Adjustment.Reinstall the pulley on the countershaft by revers-ing the removal procedure.Driven pulley end-play is 0 (zero).


ADJUSTMENT7, SpringGeneralIt is usual to experience spring setting duringbreaking period of a new spring. The factory springpreload is slightly higher (about 1 kg (2 lb)) to com-pensate for spring setting. Specifications in TECH-NICAL DATA are applicable after break-in period(about 10 hours of use).

Spring Torsional Pre-LoadTo check spring pre-load adjustment, use springscale hook (P/N 529 006 500) and a spring scale.Remove drive belt.Install the hook on the sliding half. Preventingfixed half from turning, pull sliding half with thespring scale perpendicularly with pulley axle.Take 1st measurement when sliding half begins toturn. Rotate sliding half to 10 mm (3/8 in) of rota-tion. Hold spring scale at this position. Slowly re-lease tension from spring scale and take 2nd mea-surement when sliding half begins to return. Springpre-load is the average measurement betweenthese 2.

DRIVEN PULLEY BUSHING WEAR LIMITmm (in)

Small bushing 38.30 (1.508)

Large bushing 89.15 (3.510)

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05-04-8 MMR2002_088_05_04A.FM

TYPICAL

Step : 1st measurement Step : 2nd measurement

To adjust spring pre-load, relocate spring end incam, moving it clockwise to increase the pre-loadand counterclockwise to decrease it. Refer toTECHNICAL DATA.NOTE: If spring pre-load can not be adjusted, tryto relocate the other end of spring in sliding pulley(holes A, B and C).

TYPICALLetters and numbers shown in illustration are actual letters and numbers embossed on parts

NOTE: Always recheck torsional pre-load after ad-justing.

Pulley Alignment and Drive Belt HeightRefer to PULLEY DISTANCE AND ALIGNMENTand DRIVE BELT to perform adjustments.Drive belt height is adjusted by turning Allenscrews no. 13 equally and accordingly.CAUTION: Drive belt and pulley adjustmentsmust always be checked whenever pulleys havebeen removed, replaced or disassembled.

5, CamMake sure to install proper cam. Refer to TECHNI-CAL DATA.Cam angle is identified on cam.

NOTE: For high altitude regions, a service bulletinwill give information about calibration according toaltitude.

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05-04-10 MMR2002_088_05_04A.FM

REMOVALRemove guard and drive belt from vehicle.Remove cap screw no. 1 and shouldered washerno. 13 then pull the driven pulley from the coun-tershaft.Note shouldered washer position for reinstallation.Take care not to loose spacer no. 4.

1. Spacer2. Shoulder on this side3. Concave side facing driven pulley

5, Countershaft Should countershaft no. 5 removal be required,refer to BRAKE then look for Countershaft andBrake Disc Removal.


Remove half keys no. 6 and washer no. 7 to dis-assemble the cam and the 2 pulley halves.

CLEANING

8,9, Large Bushing and Small BushingDuring break-in period (about 10 hours of use), te-flon from bushing moves to cam or shaft surface.A teflon over teflon running condition occurs, lead-ing to low friction. So it is normal to see gray teflondeposit on cam or shaft. Do not remove that de-posit, it is not dust.When a dust deposit has to be removed from thecam or the shaft, use dry cloth to avoid removingtransferred teflon.

Pulley Half CleaningUse Pulley Flange Cleaner (P/N 413 711 809).

INSPECTION

10, Slider ShoeCheck cam slider shoes for wear. Replace wheninside edge thickness of cam slider shoe slopebase is worn to 1 mm (.039 in) or less.


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MMR2002_088_05_04A.FM 05-04-11

ASSEMBLY

10, Cam Slider ShoeWhen replacing slider shoes, always install a newset (3 shoes) to maintain equal pressure on the cam.Install slider shoes as per following photo. REDslider shoes are being used for reverse and BLACKones for forward.

1. BLACK slider shoe2. RED slider shoe

12, ScrewsThese screws are machined at there end. With theadjustment ring steel to position 0 (zero), screwends are flush with inner side of fixed pulley halfwhen tighten.CAUTION: If any of these screws is not flush withinner side of sliding pulley, bushings will wornunequally.Assemble driven pulley components by reversingthe disassembly procedure.

11, CamCoat cam interior with anti-seize lubricant.

INSTALLATION

5, CountershaftCAUTION: Always apply anti-seize lubricant (P/N413 701 000) on the countershaft before finalpulley installation.Should installation procedure be required, refer toBRAKE then look for Brake Disc and Counter-shaft Bearing Adjustment.Reinstall the pulley on the countershaft by revers-ing the removal procedure.

Driven pulley end-play is 0 (zero).


ADJUSTMENT

Pulley Alignment and Drive Belt HeightRefer to PULLEY DISTANCE AND ALIGNMENT andDRIVE BELT to perform adjustments.Loosen screws no. 12, turn adjustment ringno. 13 then retighten screws to adjust drive beltheight.CAUTION: Drive belt and pulley adjustmentsmust always be checked whenever pulleys havebeen removed, replaced or disassembled.

11, CamMake sure to install proper cam. Refer to TECHNI-CAL DATA.Cam angle is identified on cam.

NOTE: For high altitude regions, a service bulletinwill give information about calibration according toaltitude.

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Section 05 TRANSMISSIONSubsection 05 (PULLEY DISTANCE AND ALIGNMENT)

MMR2002_089_05_05A.FM 05-05-1

PULLEY DISTANCE AND ALIGNMENT 0GENERALThe pulley distance we will refer to in this section,is the space separating the drive and driven pulleyoutside diameters (Z measurement).This basic distance is provided as an assemblyguide and indicates the dimensions betweenwhich satisfactory belt deflection will be obtained.Both pulley distance adjustment and pulley align-ment must be carried out to ensure the highestefficiency of the transmission system. Further-more, optimum drive belt operation and minimalwear will be obtained only with proper pulley align-ment.CAUTION: Before checking pulley adjustment,the rear suspension must be mounted on the ve-hicle and track tension/alignment must be done.Always check pulley adjustment after suspen-sion is adjusted.

All Pulley Alignment Specifications Refer to:X = Distance between straight bar and drive pulley

fixed half edge, measured between pulleys.Y = Distance between straight bar and drive pul-

ley fixed half edge, measured at the end ofstraight bar.

Z = Distance between outside diameter of pulleys.

GENERAL PROCEDURERemove guard and drive belt.By turning and pushing the sliding half, open thedriven pulley. Insert a straight bar 9.5 mm (.375 in)square, 48 cm (19 in) long or the proper alignmentbar into the opened driven pulley.

Measuring ProcedureUsing Straight BarAlways measure distances X and Y from the far-ther straight bar side (including its thickness to thefixed half edge).

TYPICAL1. Straight bar2. Front of vehicle

The distance Y must exceed distance X to com-pensate for the twist due to the engine torque.

Drive Belt DeflectionNOTE: When pulley distance and alignment areadjusted to specifications, refer to DRIVE BELT toadjust drive belt deflection.CAUTION: This section deals mainly with ad-justment procedures. For complete assemblyrequirements, refer to the proper ENGINE orTRANSMISSION installation section.

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05-05-2 MMR2002_089_05_05A.FM

PULLEY ALIGNMENT AND DISTANCE SPECIFICATIONS CHART

➀ Alignment bars have been made according to pulley alignment nominal values. However, they do nottake into account allowed tolerances for alignment specifications. They are used as GO/NO GO gaugesfor quick alignment and pulley distance check and as templates to reach alignment nominal values.

TYPICAL1. Engine movement2. Contact

ALIGNMENT BAR IN PULLEYS

NOTE: Prior to performing pulley adjustment,loosen torque rod nut to allow engine movement.Engine supports have tendency to stick to frame,work engine loose prior to aligning. Disconnectthe tuned pipe and air intake silencer. Clean andlubricate torque rod threads.

1. Loosen lock nut first2. Loosen

Pulley Distance Adjustment MethodEngine MovementThe engine support has slotted mounting holes.Move engine to obtain specified distance be-tween pulleys.

MODEL

PULLEYDISTANCE

OFFSET ALIGNMENT

BAR ➀P/NZ

± 0.50 mm (.020 in)X

± 0.50 mm (.020 in)Y-X

± 0.50 mm (.020 in)

ZX 380 FAN 16.5 (.650) 35.50 (1.398) 1.5 (.060) 529 035 586

ZX LIQUID WITH FORMULA 16.5 (.650) 35.50 (1.398) 1.5 (.060) 529 026 700

ZX 500 FANZX LIQUID WITH HPV 27 16.5 (.650) 35.50 (1.398) 1.5 (.060) 529 035 530

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MMR2002_089_05_05A.FM 05-05-3

Pulley Alignment MethodEngine MovementLoosen the 4 bolts retaining engine support to theframe. Position engine to obtain the specifiedalignment.NOTE: After alignment, adjust torque rod so itslightly contacts stopper plate, then turn an addi-tional half turn. Do not over tighten, it will disalignpulleys.

1. Half turn preload2. Retighten

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Section 05 TRANSMISSIONSubsection 06 (BRAKE)

MMR2002-090_05_06A.FM 05-06-1

BRAKE 0MECHANICAL BRAKELegend 380 F, MX Z 380 F and Grand Touring 380 F

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HYDRAULIC BRAKELegend 500 F, MX Z 500 F, Summit 500 F, Grand Touring 500 F and ZX Models with 493 Engines

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BRAKE PADS REPLACEMENTBrake pads must be replaced when lining is 1 mm(1/32 in) thick or less.CAUTION: Brake pads must always be replacedin pairs.

A. 1 mm (1/32 in) minimum

RemovalBrake pads removal procedure is as follows:– Remove locking tab.– Pull out caliper from the brake disc.– Remove 2 retainers from the pins.– Pull out 2 pins which releases the spring.– Remove the brake pads.

1. Locking tab

1. Retainer2. Spring3. Pin

1. Brake pad

Installation– Install new brake pads.– Install spring and push 2 pins to lock the brake

pads.– Install 2 retainers in the pin holes.– Install brake pad caliper on the brake disc.– Install locking tab.To install brake, reverse removal procedure pay at-tention to the following.

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MMR2002-090_05_06A.FM 05-06-5

Each time a new caliper or new brake pads areinstalled, proceed with the following:– With caliper not bolted to chaincase, apply brake

few times until both new pads are touching eachother.

– Push back pads and repeat above step.– Push back pads then fasten caliper to chaincase.– Proceed with bleeding as described in this sub-

section.

REMOVALBRAKE DISC REMOVAL

Models with Hydraulic Brake

Brake disc can be removed without removingchaincase. Proceed as follows:– Remove belt guard, belt and driven pulley.– Remove air silencer.– Unbolt bearing support no. 4 from chassis.– Unscrew caliper from chaincase.– Open chaincase and remove upper sprocket.– Pull countershaft no. 3 toward driven pulley

side to free from chaincase and disc.– Remove disc.

COUNTERSHAFT BEARING REMOVALUnbolt bearing support. Install screw from remov-er (P/N 529 035 699).

Install remover (P/N 529 035 699) on countershaftfor complete bearing removal.

1. Bearing

COUNTERSHAFT REMOVAL

Models with 593, 693 and 793 engines

Proceed the same as for brake disc and counter-shaft bearing removal and then remove the coun-tershaft.

Models 380 F, 500 F and 500 LC

– Remove caliper.– Remove guard, belt and driven pulley.– Remove air silencer.– Unbolt bearing support no. 19 from chassis.– Open chaincase and remove upper sprocket.– Pull countershaft assembly toward driven pulley

side to gain access to clip no. 25.– Remove clip no. 25 on countershaft.

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05-06-6 MMR2002-090_05_06A.FM

– Pull countershaft toward driven pulley side tofree from chaincase and disc.

– Remove disc.

DISASSEMBLY7,15,16,23, Brake Pad, Brake Lever, Pin and ScrewModels with Mechanical Brake

Pull pin out of caliper and remove lever.Fixed pad is riveted to chaincase on these models.Caliper must be split to remove moving pad. Toremoved fixed pad, drill out its rivet then pry discin order to free fixed pad.


Only brake pads are available as spare parts. If cal-iper or master cylinder are damaged, replace eachof them as an assembly.

CLEANINGClean all metal components in a general purposesolvent. Thoroughly dry all components before as-sembling.CAUTION: Do not clean brake pads in solvent.Soiled brake pads must be replaced by new ones.

INSPECTION7, Brake PadModels with Mechanical Brake

Brake pads must be replaced when fixed padprojects only 1 mm (1/32 in) from caliper.

CAUTION: Brake pads must always be replacedin pairs.

TYPICAL1. Fixed pad2. Inner caliperA. 1 mm (1/32 in) minimum


Brake pads must be replaced when lining is 1 mm(1/32 in) thick or less. Refer to the photo in BRAKEPADS REPLACEMENT.

17, Brake DiscCheck for scoring, cracking or bending, replace asrequired.CAUTION: Brake disc should never be machined.

ASSEMBLYModels with Mechanical Brake

14, Ratchet WheelApply synthetic grease (P/N 413 711 500) on threadsand spring seat prior to installing. Fully tighten thenback off one turn.

16, PinInstall so that it can only be removed upward. Lockit in the caliper casting notch.

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MMR2002-090_05_06A.FM 05-06-7

INSTALLATION17, Brake DiscModels with Mechanical Brake

The brake disc must be floating on countershaftfor efficient operation of brake.Apply anti-seize lubricant (P/N 293 800 070) onshaft and check that disc slides freely.The disc hub exceeds the disc more from one sidethan from the other. Install disc with the longerexceeding portion toward driven pulley.Push O-rings inside disc hub.


Apply anti-seize lubricant (P/N 293 800 070) on shaft.The disc hub exceeds the disc more from one sidethan from the other. Install disc with the longerexceeding portion toward driven pulley.

7, Brake Pad


After brake pads installation, brake disc must becentered in caliper. Apply brake then check forproper brake disc positioning.Push on appropriate caliper piston in order tomove pad inward allowing proper brake disc posi-tioning.

1. Brake disc not centered2. Brake disc centered3. Apply brake before checking

Apply brake then recheck.

Countershaft Bearing AdjustmentInsert countershaft (with brake disc) from chain-case side through countershaft support (drivenpulley side), then insert into chaincase.Install countershaft bearing no. 19 using proper tool.To install bearing on countershaft, use remover(P/N 529 030 100) and some flat washers of 3 mm(1/8 in) total thickness. Using original retainingscrew and shouldered washer tighten until bearingrests against circlip.

1. Washers use as a 3 mm (1/8 in) spacer2. Original retaining screw and shouldered washer3. Bearing against circlip

Ensure that countershaft is properly aligned, thentighten 3 retaining screws.NOTE: A misaligned countershaft will result in dif-ficulty to center the bearing in its support.Torque castellated nut of upper sprocket to 45 to75 N•m (33 to 55 lbf•ft).Close chaincase referring to CHAINCASE.

1,11,12, Locking Tab, Outer Caliperand NutInstall caliper retaining bolts.Assemble outer caliper. Install locking tab thennuts. Torque nuts to 24 N•m (18 lbf•ft). Bend lock-ing tab over a flat of each nut.

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05-06-8 MMR2002-090_05_06A.FM

5,12, Brake Cable and NutInsert brake cable into upper hole in brake leverand caliper. Install nut and tighten until a fewthreads exceed.

10, Upper ClampInstall upper clamp with its arrow pointing at frontof vehicle. Tighten to 8 N•m (71 lbf•in) front screwbefore rear one.

TYPICAL1. Arrow on upper clamp pointing at front of vehicle2. Tighten front screw first

ADJUSTMENTBrakeModels with Mechanical Brake

Fully depress brake handle several times to obtain13 mm (1/2 in) between brake handle and handle-bar grip when brake is fully applied.

A. 13 mm (1/2 in)

Should this adjustment be unattainable, retightennut no. 12 as needed.


Change brake fluid once a year.Bleed brake system as follows:Keep sufficient DOT 4 brake fluid in reservoir at alltimes.CAUTION: Use only DOT 4 brake fluid.Install a hose on left side bleeder. Route this hoseto a container. Open bleeder.Pump brake lever until no air escapes from hose.Close bleeder.Proceed the same way with the right side bleeder.

TYPICAL1. Open bleeder 2. Clear hose to catch used brake fluid

5, Brake Light Switch

Models with Mechanical Brake

Brake light should light up before brake pads touchbrake disc. To adjust, unscrew nut no. 12 untilbrake light goes on.

Check brake adjustment as described above.NOTE: If brake light adjustment is unattainablewhile respecting brake adjustment, ratchet wheelmay be too far out. If so, tighten ratchet wheel.


There is no adjustment on these models. Checkthat switch is securely installed.

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MMR2002-090_05_06A.FM 05-06-9

BLEEDINGChange brake fluid once a year.Bleed brake system as follows:Keep sufficient DOT 4 brake fluid in reservoir at alltimes.CAUTION: Use only DOT 4 brake fluid.Install a clear hose on left side bleeder. Route thishose to a container. Open bleeder.Pump brake lever until no air escapes from hose.Close bleeder.Proceed the same way with the right side bleeder.

TYPICAL1. Open bleeder 2. Clear hose to catch used brake fluid

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Section 05 TRANSMISSIONSubsection 07 (CHAINCASE)

MMR2002-091_05_07A.FM 05-07-1

CHAINCASE 0

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REMOVAL AND DISASSEMBLYTo remove chaincase proceed as follows.Remove tuned pipes and muffler.

Remove hair pin no. 8. Release drive chain ten-sion by unscrewing tensioner adjustment screw.Drain oil by removing drain plug no. 24.

3,4,5,6,13,16,17, Cotter Pin, Nut, Sprocket, Shim and Drive ChainApply parking brake.Remove cotter pin no. 3 and nut no. 4 retainingupper sprocket no. 5 and screw no. 15 retaininglower sprocket no. 16. Pull sprockets and drivechain simultaneously. Remove shims nos. 6 and 17.NOTE: Should countershaft removal be required,refer to BRAKE then look for Countershaft Re-moval.Release parking brake.Remove 3 nuts no. 14.Unfold locking tab no. 23 then remove caliper re-taining screws no. 22.Release track tension, use drive axle holder no. 20(P/N 529 007 200).

1. Drive axle2. Suspension front arm upper axle

Pry out drive axle oil seal no. 19 from chaincase.Pull chaincase from drive axle and countershaft.Using 2 large prybars inserted between chaincasehousing no. 7 and frame, pry complete assemblyfrom vehicle.

CHAINCASE HOUSING REMOVAL

INSPECTIONVisually inspect the chain for cracked, damaged ormissing links. Check for worn or defective bear-ings, sprockets and chain tensioner components.

GEAR RATIO MODIFICATIONFor particular applications, the number of teeth ofthe sprockets can be increased or decreased onlower and upper sprockets.Refer to TECHNICAL DATA for gear ratios.CAUTION: Gear ratio modifications shouldonly be performed by experienced mechanicssince they can greatly affect vehicle perfor-mance.NOTE: For high altitude regions, a service bulletinwill give information about calibration according toaltitude.

� WARNING

Never remove exhaust components when en-gine is hot.

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MMR2002-091_05_07A.FM 05-07-3

INSTALLATION AND ASSEMBLYReverse removal and disassembly procedure andpay attention to the following. Replace oil seals, gas-kets O-rings and drain plug.

25, Hardened Washer

793 Engine Equipped Models Only

Make sure to install a hardened washer on eachend of spring.

1. Hardened washers

All Models

11, Oil SealUsing an appropriate pusher, press the oil seal intochaincase hub. Oil seal must fit flush with the chain-case edge.NOTE: Should installation procedure for counter-shaft be required, refer to BRAKE.

5,16, SprocketsPosition the sprockets with the writing facing thechaincase cover. Sprocket hub faces toward chain-case.

4, Upper Sprocket Castellated NutTorque to 45 to 75 N•m (33 to 55 lbf•ft).Install new cotter pin in the position shown.CAUTION: When removing a cotter pin alwaysreplace with a new one.CAUTION: Cotter pin will rub on chaincase cov-er if installed otherwise.

1. New2. Fold cotter pin over castellated nut flats only

18, CirclipCAUTION: It is of the utmost importance to in-stall the circlip otherwise damage to the chain-case components may occur.

DRIVE CHAIN ADJUSTMENTNOTE: Brake disc key must be in good conditionbefore checking chain free play.

10, O-RingReplace O-ring no. 10 on tensioner adjustmentscrew. Fully tighten tensioner adjustment screwby hand, then back off only far enough for hair pinto engage in locking hole.This initial adjustment should provide 3 - 5 mm(1/8 - 13/64 in) free-play when measured at theouter circumference of the brake disc.CAUTION: Free-play must not exceed 5 mm(13/64 in), readjust if necessary.

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05-07-4 MMR2002-091_05_07A.FM

21, Chaincase OilPour 250 mL (8.5 U.S. oz) of synthetic chaincaseoil (P/N 413 803 300) into chaincase.NOTE: Chaincase oil capacity is 250 mL (8.5 U.S. oz).Check oil level with the dipstick then add if re-quired. Remove metal particles from magnet.

TYPICAL1. Dipstick 2. Oil level3. Level between marks4. Magnet

NOTE: Chaincase must be in its proper positionwhen checking oil level.

ADJUSTMENT

Pulley AlignmentRefer to PULLEY DISTANCE AND ALIGNMENT.

Track Tension and AlignmentRefer to TRACK.

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Section 05 TRANSMISSIONSubsection 08 (DRIVE CHAIN)

MMR2002-092_05_08A.FM 05-08-1

DRIVE CHAIN 0SILENT CHAINThere are 2 types of silent chains. One is 11-plateswide and the other is 13-plates wide (stronger). Donot interchange chains. Fit chain on top sprocketto make sure that you are using right one accord-ing to width. Refer to TECHNICAL DATA.NOTE: No work (separation, lengthening) can bedone on the silent chain type.

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