Servicing Center Crankcase Components - Tracker Off-Road 500S Service Manual

8. Remove the secondary drive gear/secondary driven
gear retaining nut. From inside the crankcase using a
rubber mallet, drive out the output shaft assembly.
Account for the output shaft, a shim, a washer, and
the nut.
AT THIS POINT
To service crankshaft assembly, see Servicing Center
Crankcase Components sub-section.
Servicing Center
Crankcase Components
SECONDARY GEARS
 NOTE: When checking and correcting secondary
gear backlash and tooth contact, the universal joint
must be secured to the front shaft or false measure-
ments will occur.
Checking Backlash
NOTE: The rear shaft and bevel gear must be

removed for this procedure. Also, always start with
the original shims on the rear shaft.
1. Place the left-side crankcase cover onto the left-side
crankcase half to prevent runout of the secondary
transmission output shaft.
2. Install the secondary driven output shaft assembly
onto the crankcase.
3. Mount the indicator tip of the dial indicator on the
secondary driven bevel gear (centered on the gear
tooth).
4. While rocking the driven bevel gear back and forth,
note the maximum backlash reading on the gauge.
5. Acceptable backlash range is 0.05-0.33 mm (0.002-
0.013 in.).
Correcting Backlash
 NOTE: If backlash measurement is within the
acceptable range, no correction is necessary.
1. If backlash measurement is less than specified,
remove an existing shim, measure it, and install a
new thinner shim.
2. If backlash measurement is more than specified,
remove an existing shim, measure it, and install a
thicker shim.
 NOTE: Continue to remove, measure, and install
until backlash measurement is within tolerance. Note
the following chart:
Backlash Measurement
Under 0.05 mm (0.002 in.)
At 0.05-0.33 mm (0.002-0.013 in.)
Over 0.33 mm (0.013 in.)
Shim Correction
Decrease Shim Thickness
No Correction Required
Increase Shim Thickness
Checking Tooth Contact
NOTE: After correcting backlash of the secondary

driven bevel gear, it is necessary to check tooth con-
tact.
1. Remove the secondary driven output shaft assembly
from the left-side crankcase half.
2. Clean the secondary driven bevel gear teeth of old oil
and grease residue.
3. Apply a thin, even coat of a machinist-layout dye to
several teeth of the gear.
4. Install the secondary driven output shaft assembly.
5. Rotate the secondary driven bevel gear several revo-
lutions in both directions.
6. Examine the tooth contact pattern in the dye and
compare the pattern to the illustrations.
ATV-0103
ATV-0105
ATV-0104
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