Differential Removal - Honda TRX500FM Service Manual

Set a horizontal type dial indicator on the ring gear
through the filler hole.
Tum the ring gear back and forth to read backlash.
STANDARD: 0.05 - 0.25 mm (0.002 - 0.010 in)
SERVICE LIMIT: 0.4 mm (0.02 in)
Remove the dial indicator. Turn the ring gear 120 0 and
measure backlash. Repeal this procedure once more.
Compare the difference of the three measurements.
C
FRONT DRIVING MECHANISM
SERVICE LIMIT: 0.2 mm (0.01 In )
If the difference in measurements exceeds the service
limit, it indicates that the bearing is not installed
squarely, or the case is deformed .
Inspect the bearings and case.
If
the backlash is excessive, replace the ring gear left
r - - - - - - - - - - - - - - - - - - ,
side shim with a thinner one.
If the backlash is too small, replace the ring gear left
side shim with a thicker one.
The backlash is changed by about 0.06 mm (0.002 in)
when the thickness of the shim is changed by 0.10 mm
(0.004 in).
NOTE-
Twenty-three different thickness shims are available
from the thinnest (0.50 mm thickness: A) shim to the
thickest (1.60 mm thickness: W) in intervals of
0.05 mm.
Ring gear shims :
A : (thinnest): 0.50 mm (0.020 In)
K : (standard): 1.00 mm (0.039 in)
W: (th ickest): 1.60 mm (0.063 in)
Change the right side shim as follows: If the left shim
was replaced with a 0.10 mm (0.004 in) thicker shim,
replace the right shim with one that is 0.10 mm
(0.004 in) thinner.
DIFFERENTIAL REMOVAL
loosen the sil( cover bolts [1] in a crisscross pattern in
several steps and remove them.
Pry the final gear case cover [2] at the points (3] as
shown by using a screwdriver and remove it.
Right Shim
left Shim
. ....-.-
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