Honda TRX500FM Service Manual page 413

It
is important 10
tum
/fie
pinion gear
while tightening Ihe
bolts. /f the ring
gesr shIm Is 100
thICk, the
gears
will
lock after only light
lightening.
lostall the case cover and lighten the bolts [ 1] in several
steps untillhe cover [2] evenly touches the gear case.
Then. while rotating the pinion gear, lighten the bolts to
the specified torque in a crisscross pattern in several
steps.
TORQUE : 10 mm bolt: 47 N'm (4.8 kgf'm, 351bHt)
8
mm
bolt: 25 N'm (2.5 kgf'm, 181bHI)
FRONT DRIVING MECHANISM
mm)
Rotate the ring gear several limes in both directions of
rotation. Normal : Heel
Check the gear tooth contact pattern through the oil ;
filler hole. .... Toe
The pattern is indicated by the Prussian Blue appliecllo
the pinion.
Contact is normal if the Prussian Blue is transferred 10
the
approxImate
center of each tooth, but slightly to the
heel side and to the flank side.
If the patterns are not correct, remove and change the
pinion shim with one of an alternate thickness.
Face __ __ Face
Flank
Coast side
Replace the pinion shim
[ 1 J
With a thicker one if the
contact pattern is too high, toward the face. Too High:
[1[
Fa",
Ie?
Drive side Coast side
Replace the pinion shim
[ 1 ]
with a thinner one if the
contact pattern is too low, toward the flank.
The pattern will shift about 0.5 - 1.0 mm (0.02 - 0.04 in)
when the thickness of the shim is changed by 0. 12 mm
(0.005 in).
NOTE :
Fifleen different thickness shims are available from
the thinnest
(1.64
mm thickness:
A)
shim to the
thickest (2.48 mm thickness: 0) in intervals of
0.06
mm.
Pinion shims:
A:
(thinnest):
1.64
mm
(0.065
In)
G: (standard): 2.00 mm (0.079 In)
0 :
(thickest): 2.48 mm (0.098 In)
Pinion shim replacement (page 19-29).
Drive side
I I
Coast side
Flank Flank
19-25