Front crankcase cover. 1 - diaphragm mechanism, 2 - gasket, 3 - actuator housing, 4 - gasket, 5 - front crankcase cover, 6 - fork stem, 7 - retaining ring, 8 - four-wheel drive fork, 9 - spring, 10 - thrust washer, 11 - all-wheel drive clutch, 12 - front output shaft, 13 - oil seal, 14 - bearing, 15 - retaining ring, 16 - oil flinger, 17 - oil seal, 18 - connecting flange, 19 - thrust washer, 20 - lock nut.
Disassembly
1. Remove the all-wheel drive enable sensor.
2. Removing the pneumatic actuator.
A) Unscrew the four bolts and remove the diaphragm mechanism together with the gasket.
b) Remove the all-wheel drive lever and remove the lever axle.
V) Remove the four bolts and remove the actuator housing along with the gasket.
3. Remove the all-wheel drive clutch together with the fork assembly.
4. Disassembly of the all-wheel drive fork.
A) Turn away a bolt, remove a washer, a spring and a fork from a rod.
b) Remove the retaining ring from the stem.
5. Removing the connecting flange.
A) Clamp the connecting flange in a vise. Using a hammer and chisel, loosen the caulked part of the locknut.
b) While holding the flange with the special tool, remove the lock nut, then remove the washer and connecting flange.
6. Press the front output shaft out of the front crankcase cover.
Examination
1. Checking the all-wheel drive clutch.
A) Using a feeler gauge, measure the clearance between the clutch and the 4WD fork.
Limit clearance - 1.0 mm
b) Mount the clutch on the front output shaft and check that the clutch rotates smoothly.
2. Replacing the seals in the front crankcase cover (if necessary).
A) Using a flat blade screwdriver, remove the oil seal from the front cover.
b) Using a mandrel and a hammer, press in a new oil seal.
V) Apply grease to the seal lip.
3. Front output shaft bearing replacement (if necessary).
A) Remove the front output shaft seal and oil guard from the front cover. Using a flat blade screwdriver, remove the retaining ring.
b) Press the bearing out of the front cover and press in the new bearing.
V) Install the circlip, then install the flinger and new oil seal.
Assembly
1. Press the front output shaft into the front crankcase cover.
2. Installation of the connecting flange.
A) Install the connecting flange, washer and locknut. While holding the flange with the special tool, tighten the locknut.
Tightening torque - 127 N.m
b) Clamp the connecting flange in a vise. Using a hammer and chisel, caulk the locknut.
3. Assembling the all-wheel drive fork.
A) Install the retaining ring on the fork stem.
b) Install the yoke, spring and washer onto the stem. Tighten the mounting bolt.
Tightening torque - 18 N.m
4. Install the 4WD clutch with yoke assembly.
5. Installing the pneumatic actuator.
A) Clean the bolts and bolt holes of sealant residue.
b) Apply sealant to the threads of the actuator housing mounting bolts.
Sealant: Part No. 088330-00070 Three Bond 1324 or equivalent
V) Install the actuator housing with a new gasket on the front crankcase cover and tighten the mounting bolts.
Tightening torque - 18 N.m
G) Apply grease to the axle and arm bearings.
d) Establish an axis of the lever and the lever of inclusion of a full drive.
e) Install the diaphragm mechanism with a new gasket on the actuator housing and tighten the mounting bolts.
Tightening torque - 18 N.m
6. Establish the gauge of inclusion of a full drive.