Honda 2005 FOURTRAX FOREMAN TRX500 TM Service Manual page 341

REAR DRIVING MECHANISM
Use a screwdriver
to pry the pinion
joint up by levering
against one of the
studs and the step
in the joint. Rotate
the joint in small
steps as you pry
the joint up.
Replace the pinion gear shim with a thicker one if
the contact pattern is too high, toward the face.
Replace the pinion gear shim with a thinner one if
the contact pattern is too low, toward the flank.
The pattern will shift about 0.5 - 1.0 mm (0.02 -
0.04 in) when the thickness of the shim is changed
by 0.12 mm (0.005 in).
Pinion gear shims:
A: 1.64 mm (0.065 in)
B: 1.70 mm (0.067 in)
C: 1.76 mm (0.069 in)
D: 1.82 mm (0.072 in)
E: 1.88 mm (0.074 in)
F: 1.94 mm (0.076 in)
G: 2.00 mm (0.079 in)
H: 2.06 mm (0.081 in)
I: 2.12 mm (0.083 in)
J: 2.18 mm (0.086 in)
For pinion shim replacement, see page 17-16.
PINION GEAR REMOVAL
Remove the pinion joint from the pinion gear by
pulling it to force the stopper ring at the pinion gear
shaft end past the groove in the pinion joint.
TOO HIGH: PINION GEAR SHIM
FACE
FACE
Drive side Coast side
TOO LOW:
PINION GEAR SHIM
FLANK ^ ^ FLANK
Drive side Coast side
PINION JOINT
STEP
STUD
Remove the oil seal from the gear case.
Remove the stopper ring and O-ring from the pinion
gear shaft.
OIL SEAL
STOPPER RING : - **- O-RING
17-15