Kawasaki WORKHORSE 250 (2003) [192/322] Bevel gear backlash front
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Kawasaki WORKHORSE 250 (2003) [192/322] Bevel gear backlash front

Kawasaki WORKHORSE 250 (2003) [192/322] Bevel gear backlash front
11-14 FINAL DRIVE
Output Bevel Gear Case
•
Set up a dial gauge [A] against the driven gear shaft nut
[B] to check gear backlash.
•
To measure the backlash, turn the shaft clockwise and
counterclockwise [C] slightly while holding the output
drive gear steady. The difference between the highest
and lowest gauge reading is the amount of backlash.
○
To hold the output drive gear steady, hold the shift drum
at the full-turned position.
If the backlash is not within the limit, replace the shim(s)
at the drive and/or driven gear.
Change the thickness a little at a time.
•
Recheck the backlash, and readjust as necessary.
Bevel Gea r Backlash (Front)
Standard:
0.06 ∼ 0.13 mm
(0.0024 ∼ 0.0051 in.) (at driven gear
shaft nut)
Tooth contact adjustment
•
Clean any dirt and oil off the bevel gear teeth.
•
Apply checking compound to 4 or 5 teeth on the output
driven bevel gear.
NOTE
○
Apply checking compound to the teeth in a thin, even
coat with a fairly stiff paint brush. If painted too thickly,
the exact tooth pattern may not appear.
○
The checking compound must be smooth and firm with
the consistency of tooth paste.
○
Special compounds are available from automotive sup-
ply stores for the purpose of c hecking differential gear
tooth patterns and contact. Use this for checking the
bevel gears.
•
Turn the front end of the output driven shaft for 3 or 4 turns
in the drive and reverse (coast) directions, while creating
a drag on the drive bevel gear.
Special Tool - Pinion Gear Holder: 57001-1281
•
Check the drive pattern and coast pattern of the bevel
gear teeth. The tooth contact patterns of both drive and
coast sides should be centrally located between the top
and bottom of the tooth, and a little closer to the toe of the
tooth.
If the tooth contact pattern is incorrect, replace the shim(s)
at the drive bevel gear and shim(s) at the driven bevel
gear, following the examples shown. Then erase the tooth
contact patterns, and check them again. Also check the
backlash every time the shims are replaced. Repeat the
shim change procedure as necessary.
NOTE
○
If the backlash is out of the standard range after chang-
ing shims, correct the backlash before checking the
tooth contact pattern.

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