Assembling Crankcase Half; Countershaft - Arctic Cat 2007 Service Manual

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COUNTERSHAFT

! CAUTION
When disassembling the countershaft, care must be
taken to note the direction each major component
(dog, gear) faces. If a major component is installed
facing the wrong direction, transmission damage
may occur and/or the transmission will malfunction.
In either case, complete disassembly and assembly
will be required.
KEY
1. Countershaft
2. Drive Gear #2
3. Reverse Driven Gear Dog
4. Circlip
5. Reverse Driven Gear Spacer
6. Washer
7. Reverse Driven Gear
8. Bearing
9. Bushing
10. Lock Washer
11. Lock Washer
Disassembling
From the right side:
1. Remove the right drive gear washer (17); then
remove drive gear #2 (2).
2. Remove the reverse driven gear dog (3); then
remove the circlip (4).
3. Remove the reverse driven gear spacer (5); then
remove the circlip (4).
4. In order, remove washer (6), reverse driven gear
(7), bearing (8), and bushing (9).
5. In order, remove washer (6), lock washer (10,
lock washer (11), and low driven gear (12).
6. In order, remove bearing (8), bushing (9), and
driven gear washer (13).
From the left side:
1. Remove the left drive gear washer (16); then
remove the high driven gear (15) and bearing (8).
2. In order, remove bushing (9), driven gear washer
(13), and sliding dog (14).
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12. Low Driven Gear
13. Driven Gear Washer
14. Sliding Dog
15. High Driven Gear
16. Drive Gear Washer (L)
17. Drive Gear Washer (R)
739-954A
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Assembling
From the left side:
1. Install the sliding dog (14), driven gear washer
(13), and bushing (9).
2. Install bearing (8) and high driven gear (15);
then install the left drive gear washer (16).
From the right side:
1. Install driven gear washer (13), bushing (9),
bearing (8), and low driven gear (12).
2. Install lock washer (11), lock washer (10),
washer (6), and bushing (9).
3. Install bearing (8), reverse driven gear (7),
washer (6), and the circlip (4).
4. Install reverse driven gear spacer (5), circlip (4),
reverse driven gear dog (3), and drive gear #2
(2); then install the right drive gear washer (17).
NOTE: When installing the countershaft assem-
bly, account for the washer on each end of the shaft.
Assembling Crankcase
Half
1. Install the output shaft assembly into the crank-
case making sure the two gears, shim, washer,
and nut are properly sequenced.
NOTE: The beveled side of the secondary drive
gear must face upward.
2. Apply red Loctite #271 to the threads of the out-
put shaft; then secure with the nut. Tighten nut
to specifications; then using a punch, peen the
nut.
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