KYMCO 2006 MXU 500 Off-Road Owner's Manual page 481

13
. DRIVE TRAIN
TOOTH CONTACT
After backlash adjustment and left side shim
selection are carried out, the tooth contact
must be checked. Pay attention to the
following points:
Remove the drive ring gear.
Clean and degrease several teeth on the
ring gear and pinion gear, and then apply
a coating of machinist's layout dye or
paste to several teeth of the pinion gear.
Install the removed left and right side
shims and front drive assembly.
Assembly the gear case.
＊
Do not apply a sealant to the mating
surface of the gear case.
Do not apply a sealant to the case
bolts.
Torque:
Gear case bolts:
2.3 kgf-m (23 N-m, 16.5 lbf-ft)
Rotate the drive ring gear several turns in
each direction. This will provide a contact
pattern on the coated teeth of ring gear.
Remove the drive ring gear and compare
the coated teeth to the examples shown in
(1), (2) and (3).
If tooth contact is found to be correct
(example (2)), go to the "FRONT
DRIVE DISASSEMBLY/
INSPECTION/ASSEMBLY" section in
this chapter) to complete installation.
If tooth contact is found to be incorrect
(example (1) and (3)), the shim must be
changed and the tooth contact should be
rechecked until correct.
＊
Make sure to check the backlash and
shim thickness after the tooth contact has
been adjusted, since it may have
changed. Adjust the tooth contact and
backlash until they are both within
specification. If the correct tooth contact
cannot be maintained when adjusting the
backlash, replace the pinion gear and
ring gear as a set.
13-35
(1)
Incorrect: Contact at tooth top
(2)
Correct
(3)
Incorrect: Contact at tooth root
MXU 500