Aligning The Middle Gear - Yamaha XT1200Z 2010 Service Manual

Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys
11.Measure:
• Middle gear backlash
Out of specification → Refer to "MEASUR-
ING THE MIDDLE GEAR BACKLASH" on
page 5-121.
EAS25930

ALIGNING THE MIDDLE GEAR

TIP
Aligning the middle gear is necessary when any
of the following parts are replaced:
• Crankcase
• Middle drive pinion gear
• Middle driven pinion gear
• Middle driven pinion gear bearing housing
1. Select:
• Middle drive pinion gear shim(s) "1"
• Middle driven pinion gear shim(s) "2"
TIP
Select the middle driven pinion gear shim(s) "2"
by calculating the middle drive pinion gear shim
thickness and then measuring the middle gear
backlash.
a
A
1
f
g
e
d
B
2
A. Middle drive pinion gear shim thickness
B. Middle driven pinion gear shim thickness
email: info@motomatrix.co.uk
b
c
M MMM M MMM M M MMM M
a. Position the middle gears with the appropri-
ate shim(s) that has had its respective thick-
ness calculated from information marked on
the upper crankcase, middle driven pinion
gear, and bearing housings.
b. To find middle drive pinion gear shim thick-
ness "A", use the following formula.
Middle drive pinion gear shim thickness
"A" = "a" + "b" - "c" - 0.1
"a"= a numeral on the middle drive pinion
gear bearing housing, to be divided by 100
and added to "14.00"
"b"= 52.20
"c"= a numeral on the upper crankcase, to be
divided by 100 and added to "66.00"
Example:
If the middle drive pinion gear bearing hous-
ing is marked "57"
"a" is 14.57 (i.e., 14.00 + 0.57 = 14.57)
"b" is 52.20
If the upper crankcase is marked "18"
"c" is 66.18 (i.e., 66.00 + 0.18 = 66.18)
"A" = 14.57 + 52.20 - 66.18 - 0.1 = 0.49
Round off to the hundredths digit and select
the appropriate shim(s).
TIP
In the above example, the calculated number is
0.49. The chart instructs you to round off the 9 to
10. Thus, the shim thickness is 0.50 mm.
5-123
MIDDLE GEAR
M MMM M M MMM M M MMM M MMM
a
c