Honda 2005 FOURTRAX FOREMAN TRX500 TM Service Manual page 309

FRONT DRIVING MECHANISM (FM/FE models)
BACKLASH INSPECTION
Hold the pinion gear with the special tools.
Set the final gear case into a jig or vise with soft
jaws.
Install the differential inspection tool into the right
side of the final gear.
TOOL:
Differential inspection tool 07KMK-HC50101 or
07KMK-HC5010A
(U.S.A. only)
Set a horizontal type dial indicator on the ring gear
through the filler hole.
Turn the ring gear back and forth to read backlash.
STANDARD: 0.05 - 0.25 mm (0.002 - 0.010 in)
SERVICE LIMIT: 0.4 mm (0.02 in)
Remove the dial indicator. Turn the ring gear 120°
and measure backlash. Repeat this procedure once
more.
Compare the difference of the three measurements.
SERVICE LIMIT: 0.2 mm (0.01 in)
If the difference in measurements exceeds the ser-
vice limit, it indicates that the bearing is not
installed squarely, or the case is deformed.
Inspect the bearings and case.
If the backlash is excessive, replace the ring gear left
side shim with a thinner one.
If the backlash is too small, replace the ring gear left
side shim with a thicker one.
The backlash is changed by about 0.06 mm (0.002
in) when the thickness of the shim is changed by
0.10 mm (0.004 in).
NOTE:
• Twenty-three different thickness shims are avail-
able from the thinnest (0.50 mm thickness: A)
shim to the thickest (1.60 mm thickness: W) in
intervals of 0.05 mm.
Ring gear shims:
A: (thinnest): 0.50 mm (0.020 in)
K: (standard): 1.00 mm (0.039 in)
W: (thickest): 1.60 mm (0.063 in)
Change the right side shim as follows: If the left
shim was replaced with a 0.10 mm (0.004 in) thicker
shim, replace the right shim with one that is 0.10
mm (0.004 in) thinner.
RIGHT SHIM
LEFT SHIM
16-16