Arctic Cat 2009 366 Service Manual page 65

Measuring Connecting Rod
(Small End Deflection)
1. Place the crankshaft on a set of V-blocks and
mount a dial indicator and base on the surface
plate. Position the indicator contact point against
the center of the connecting rod small end journal.
2. Zero the indicator and push the small end of the
connecting rod away from the dial indicator.
3. Maximum deflection must not exceed specifications.
Measuring Connecting Rod
(Big End Side-to-Side)
1. Push the lower end of the connecting rod to one
side of the crankshaft journal.
2. Using a feeler gauge, measure the gap between the
connecting rod and crankshaft journal.
3. Acceptable gap range must be within specifications.
Measuring Connecting Rod
(Big End Width)
1. Using a calipers, measure the width of the
connecting rod at the big-end bearing.
2. Acceptable width range must be within specifications.
Measuring Crankshaft (Runout)
1. Place the crankshaft on a set of V blocks.
2. Mount a dial indicator and base on the surface
plate. Position the indicator contact at point 1 of
the crankshaft.
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3. Zero the indicator and rotate the crankshaft slowly.
! CAUTION
Care should be taken to support the connecting rod
when rotating the crankshaft.
4. Maximum runout must not exceed specifications.
NOTE: Proceed to check runout on the other end
of the crankshaft by positioning the indicator con-
tact at point 2 and following steps 3-4.
Measuring Crankshaft
(Web-to-Web)
1. Using a calipers, measure the distance from the
outside edge of one web to the outside edge of the
other web.
2. Acceptable width range must be within specifications.
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.
Disassembling
1. Remove the reverse driven gear dog; then remove
the circlip securing the reverse driven gear.
2. Remove the reverse driven gear and account for
the washer, bushing, and bearing.
3. Remove the low driven gear washer; then remove
the low driven gear. Account for the bushing and
bearing.
4. Remove the washer; then remove the circlip secur-
ing the sliding dog. Remove the sliding dog.
5. Remove the high driven gear circlip; then remove
the high driven gear. Account for the washer,
bushing, and bearing.
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