Transmission Assembly - Linhai 2004 ATV 260 Service Manual

CHAPTER 3C ENGINE 100/125/150/200
SERVICE MANUAL09.0
8. Remove output shaft.
9. Clean all components and inspect for wear.
10. Inspect engagement dogs of gears and
replace if edges are rounded.
11. Inspect gear teeth for wear, cracks, chips or
broken teeth.
12. Remove seals from transmission case.
IMPORTANT:
New seals should be installed
after the transmission is completely assembled.
13. Inspect bearings for smooth operation.
Check for excessive play between inner and
outer race.

3.4.5.2 Transmission Assembly

1. Install output shaft.
2. Before installing the front cover make sure the
sealing surfaces are clean and dry, and shafts are
fully seated in the transmission case. Apply silicon
glue to mating surfaces.
3. Reinstall cover and torque bolts in a cross
pattern in 3 steps to 14.5 ft. lbs. (20 Nm).
4. Install new output shaft seal.
5. Install pinion shaft with bearing.
6. Install retainer plate with flat side toward
bearing.
TM
7. Apply Loctite 242(Blue) to screw threads and
torque screws to 7.2 ft-lbs. (10N.m).
8. Assemble shafts and shift fork.
9. Carefully install forward/reverse shaft and
middle shaft assembly and gear cluster as a unit
into their respective bearing case areas. Tap with
a soft face hammer to seat shaft assemblies.
NOTE
Make sure shift fork pins is properly
:
positioned in the slot on selector arm.
NOTE
Be sure gear indicator switch are
:
removed from transmission case before
installing shafts.
CHAPTER 3C ENGINE PAGE.3C - 19 -