BOMBARDIER RALLY 200 2003 Shop Manual page 170

1. PTO side (crankcase)
2. MAG side (gearbox cover)
A. Thrust washer thickness (PTO side)
B. Thrust washer thickness (MAG side)
Check all bearings, bearing points, tooth flanks,
taper grooves and annular grooves. Annular grooves
must have sharp edges.
Check for condition of shift shaft plate in the front
area as per following illustration. Replace in case
of excessive wear.
1. Spring plate
2. Screw retaining the spring plate
3. Front area of spring plate arm
Assembly
NOTE: Preassemble intermediate gear shaft and
output shaft prior to insert it into crankcase PTO.
NOTE: Run all gears before installing the gear box
cover on MAG side.
Install:
NOTE: Use lubricants from the exploded view
during preassembling of gear box shafts.
– intermediate gear shaft no. 22, thrust washer
no. 28 and thrust washer no. 18
VMR2003_014_03_10A.FM
Subsection 10 (GEARBOX)
NOTE: Check axial measurement of intermediate
shaft including thrust washer no. 18 and no. 28. If
out of measurement check for wrong and/or miss-
ing thrust washers MAG/PTO.
AXIAL MEASUREMENT
NEW MINIMUM
NEW MAXIMUM
1. Intermediate shaft
2. Thrust washer PTO
3. Thrust washer MAG
A. Axial measurement
– output shaft no. 23 with main gear no. 24, shim
no. 29, needle bearing no. 30, reverse gear
sprocket no. 31 and thrust washer no. 27
– gear box chain no. 32
– shift fork no. 20.
Installation
For installation, reverse the removal procedure.
Pay attention to the following details.
Install:
– main shaft no. 25
NOTE: If necessary use a soft hammer to put
main shaft in place.
– shift shaft plate no. 21
– preassembled gear box as per following illustra-
tion.
CAUTION: Don't forget thrust washer no. 27
and no. 28.
NOTE: Check axial measurement of intermediate
gear shaft including thrust washers (see Assem-
bly above).
Section 03 ENGINE
82.00 mm (.269 ft)
82.20 mm (.270 ft)
03-10-13