Tracker Off-Road 800SX Service Manual page 167

TA102
8. If backlash measurement is more than specified,
remove the existing shim and install a thinner shim.
NOTE: Continue to remove, measure, and install

until backlash measurement is within tolerance. Note
the following chart:
Backlash Measurement
Under 0.076 mm (0.003 in.)
At 0.076-0.241 mm (0.003-0.0095 in.)
Over 0.241 mm (0.0095 in.)
9. Tape the splined portion of the pinion shaft to protect
the seal; then using an appropriate seal installer,
install the front output seal so it seats fully past the
chamfer of the case.
TA129
TA130
ASSEMBLING HALVES
1. Install the intermediate shaft and idler shaft into the
case only partially. Do not seat the shafts completely
into the case at this time.
Shim Correction
Increase Shim Thickness
No Correction Required
Decrease Shim Thickness
TA056
2. With the aid of an assistant and with the gear forks in
position, install the input shaft and reverse shaft with
chain as an assembly.
TA058
TA059
NOTE: Make sure the shift fork pins face the

installer.
NOTE: Engage all four shafts before seating them

simultaneously into the case.
NOTE: Ensure the chain stays engaged in the

sprocket teeth.
 NOTE: The shift shaft rail should remain unseated
at this point.
3. Install the shift drum into the case; then engage the
fork tabs into the grooves in the shift drum.
165