Servicing Center Crankcase Components - Arctic Cat 2015 400 Service Manual

9. Using Crankcase Separator/Crankshaft Remover,
remove the crankshaft.
CAUTION
Do not remove the remaining output shaft assembly
unless absolutely necessary. If the shaft is removed, the
shaft nut must be replaced with a new one and the shaft
must be re-shimmed.
10. Remove the secondary drive gear/secondary driven
gear retaining nut. From inside the crankcase using a
rubber mallet, drive out the output shaft assembly.
Account for the output shaft, a shim, a washer, and
the nut.
AT THIS POINT

To service crankshaft assembly, see Servicing Center
Crankcase Components sub-section.
Servicing Center
Crankcase Components
SECONDARY GEARS
 NOTE: When checking and correcting secondary
gear backlash and tooth contact, the output drive
flange must be secured to the front shaft or false
measurements will occur.
Checking Backlash
 NOTE: The rear shaft and bevel gear must be
removed for this procedure. Also, always start with
the original shims on the rear shaft.
62
1. Place the left-side crankcase cover onto the left-side
crankcase half to prevent runout of the secondary
transmission output shaft.
2. Install the secondary driven output shaft assembly
onto the crankcase.
3. Mount the indicator tip of the dial indicator on the
secondary driven bevel gear (centered on the gear
tooth).
4. While rocking the driven bevel gear back and forth,
note the maximum backlash reading on the gauge.
5. Acceptable backlash range is 0.05-0.33 mm
(0.002-0.013 in.).
MD1024
Correcting Backlash
 NOTE: If backlash measurement is within the
acceptable range, no correction is necessary.
1. If backlash measurement is less than specified,
remove an existing shim, measure it, and install a
new thinner shim.
2. If backlash measurement is more than specified,
remove an existing shim, measure it, and install a
thicker shim.
 NOTE: Continue to remove, measure, and install
until backlash measurement is within tolerance. Note
the following chart.
Backlash Measurement
MD1330
Under 0.05 mm (0.002 in.)
At 0.05-0.33 mm (0.002-0.013 in.)
Over 0.33 mm (0.013 in.)
Checking Tooth Contact
 NOTE: After correcting backlash of the secondary
driven bevel gear, it is necessary to check tooth con-
tact.
1. Remove the secondary driven output shaft assembly
from the left-side crankcase half.
2. Clean the secondary driven bevel gear teeth of old oil
and grease residue.
3. Apply a thin, even coat of a machinist-layout dye to
several teeth of the gear.
4. Install the secondary driven output shaft assembly.
5. Rotate the secondary driven bevel gear several revo-
lutions in both directions.
6. Examine the tooth contact pattern in the dye and
compare the pattern to the illustrations.
Shim Correction
Decrease Shim Thickness
No Correction Required
Increase Shim Thickness