Tracker Off-Road 800SX Service Manual page 166

TA073
NOTE: To determine the appropriate shim, start

with the thickest shim and install the snap ring. If the
snap ring will not fit in the groove, remove the shim
and install the next size smaller shim. Continue until
the snap ring can be installed.
2. With the appropriate shim in place and the O-ring
coated with molybdenum grease, install the pinion
gear assembly into the case half and secure with the
four screws. Tighten to 20 ft-lb (27.2 N-m).
TA025A
 NOTE: To determine the appropriate shim, proceed
to step 3.
3. Using an appropriate tool, lock the pinion gear in
place.
TA124A
4. Mount a dial indicator so the tip is contacting a tooth
on the pinion shaft.
164
TA096
TA095
5. While pushing in on the front output shaft, and while
rocking the shaft back and forth, note the maximum
backlash reading on the gauge.
TA125
6. Acceptable backlash range is 0.076-0.241 mm
(0.003-0.0095 in.).
 NOTE: If backlash measurement is within the
acceptable range, no correction is necessary.
7. If backlash measurement is less than specified,
remove the existing shim and install a new thicker
shim (from shim kit).