Front crankcase cover. 1 - diaphragm mechanism, 2 - gasket, 3 - actuator housing, 4 - gasket, 5 - front crankcase cover, 6 - fork rod, 7 - retaining ring, 8 - all-wheel drive engagement fork, 9 - spring, 10 - thrust washer, 11 - all-wheel drive engagement clutch, 12 - front output shaft, 13 - oil seal, 14 - bearing, 15 - retaining ring, 16 - oil deflector ring, 17 - oil seal, 18 - connecting flange, 19 - thrust washer, 20 - lock nut.
Disassembly
1. Remove the all-wheel drive engagement sensor.
2. Removing the pneumatic drive.
a) Unscrew the four bolts and remove the diaphragm mechanism together with the gasket.
b) Remove the all-wheel drive engagement lever and take out the lever axle.
c) Unscrew the four bolts and remove the actuator housing together with the gasket.
3. Remove the all-wheel drive engagement clutch together with the fork assembly.
4. Disassembling the all-wheel drive engagement fork.
a) Unscrew the bolt, remove the washer, spring and fork from the rod.
b) Remove the retaining ring from the rod.
5. Removing the connecting flange.
a) Clamp the coupling flange in a vice. Use a hammer and chisel to loosen the caulked portion of the lock nut.
b) Holding the flange with a special tool, unscrew the lock nut, then remove the washer and the connecting flange.
6. Press the front output shaft out of the front crankcase cover.
Examination
1. Checking the all-wheel drive engagement clutch.
a) Using a feeler gauge, measure the gap between the clutch and the all-wheel drive engagement fork.
Maximum clearance - 1.0 mm
b) Install the coupling on the front output shaft and check the smooth rotation of the coupling.
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 drift and hammer, press in the new seal.
c) Apply grease to the seal lip.
3. Replacing the front output shaft bearing (if necessary).
a) Remove the front output shaft seal and oil guard ring from the front cover. Use a flat-blade screwdriver to remove the retaining ring.
b) Press the bearing out of the front cover and press in a new bearing.
c) Install the retaining ring, then install the oil deflector ring and new oil seal.
Assembly
1. Press the front output shaft into the front crankcase cover.
2. Installing the connecting flange.
a) Install the connecting flange, washer and lock nut. Hold the flange with the special tool and tighten the lock nut.
Tightening torque - 127 Nm
b) Clamp the coupling flange in a vice. Use a hammer and chisel to hammer the lock nut into place.
3. Assembling the all-wheel drive engagement fork.
a) Install the retaining ring onto the fork stem.
b) Install the fork, spring and washer onto the rod. Tighten the mounting bolt.
Tightening torque - 18 Nm
4. Install the all-wheel drive engagement clutch together with the fork assembly.
5. Installation of pneumatic drive.
a) Clean the bolts and bolt holes from any remaining sealant.
b) Apply sealant to the threads of the actuator housing mounting bolts.
Sealant: Part # 088330-00070, Three Bond 1324 or equivalent
c) Install the actuator housing together with the new gasket onto the front crankcase cover and tighten the mounting bolts.
Tightening torque - 18 Nm
d) Apply grease to the axle and lever bearings.
d) Install the lever axle and the all-wheel drive engagement lever.
e) Install the diaphragm mechanism together with the new gasket onto the actuator housing and tighten the mounting bolts.
Tightening torque - 18 Nm
6. Install the all-wheel drive engagement sensor.