BRP Can-Am Rally 200 Трансмиссия

BRP Can-Am Rally 200 Трансмиссия
Section 06 DRIVE TRAIN
Subsection 01 (TABLE OF CONTENTS)
TABLE OF CONTENTS
0
FRONT DRIVE ........................................................................................................................
GENERAL ...........................................................................................................................
FRONT WHEEL HUB .........................................................................................................
06-02-1
06-02-2
06-02-2
REAR AXLE ............................................................................................................................
GENERAL ...........................................................................................................................
DRIVE CHAIN .....................................................................................................................
REAR WHEEL HUB ............................................................................................................
REAR SPROCKET AND HUB.............................................................................................
REAR AXLE ........................................................................................................................
CHAIN TENSIONER ...........................................................................................................
CHAIN TENSIONER BEARINGS .......................................................................................
SLIDER-SHOE ....................................................................................................................
CHAIN GUIDE ....................................................................................................................
CHAIN ROLLER ..................................................................................................................
06-03-1
06-03-2
06-03-2
06-03-3
06-03-4
06-03-5
06-03-6
06-03-6
06-03-7
06-03-8
06-03-8
VMR2004_112_06_01ATOC.FM
06-01-1
Section 06 DRIVE TRAIN
Subsection 02 (FRONT DRIVE)
FRONT DRIVE
0
70 N•m
(52 lbf•ft)
2
1
3
135 N•m
(100 lbf•ft)
4
8
Synthetic
grease
7
5
7
6
Synthetic
grease
8
7
7
5
6
4
2
1
70 N•m
3
(52 lbf•ft)
135 N•m
(100 lbf•ft)
V06H0LS
VMR2004_103_06_02A.FM
06-02-1
Section 06 DRIVE TRAIN
Subsection 02 (FRONT DRIVE)
GENERAL
During assembly/installation, use torque values
and service products as in the exploded view.
Clean threads before applying threadlocker. Refer
to SELF-LOCKING FASTENERS and LOCTITE APPLICATION at the beginning of this manual for
complete procedure.
 WARNING
Torque wrench tightening specifications
must strictly be adhered to.
Locking devices (ex.: locking tabs, elastic stop
nuts, self-locking fasteners, cotter pin, etc.)
must be installed or replaced with new ones
where specified. If the efficiency of a locking
device is impaired, it must be renewed.
CAUTION: During installation, make sure every
part is free from old grease and dirt. This allows
for a clean re-assembly and will avoid premature wear caused by dirt contamination.
After each job, ride the vehicle for a few minutes
and make sure the job is successful; i.e. wheels
are not loose, front brakes operate correctly, etc.
FRONT WHEEL HUB
Removal
Apply front brakes.
Remove hub rubber cap no. 1.
Remove and discard cotter pin no. 2.
Loosen front drive nut no. 3.
Lift front of vehicle and install jack stands under
the frame to support the rear of vehicle off the
ground.
Remove front wheels.
NOTE: Use the same procedure for both wheel
hubs.
Unscrew front drive nut no. 3.
Remove bushing no. 4.
V06H0MA
3
2
1
1. Cotter pin
2. Elastic nut
3. Front wheel hub
Release front brakes.
Unscrew and remove brake caliper.
Pull out wheel hub no. 6.
NOTE: The brake disk comes with the hub.
Inspection
Check wheel hub for cracks splines wear or other
damage. Change if necessary.
Check wear ring and inner sleeve for damage, if
so change them.
Check ball bearings no. 7 for damage.
Outer ball bearing replacement
Place hub on a plane surface.
Offset inner sleeve no. 8. Using a hammer and a
punch, eject defective bearing.
NOTE: Be careful not to damage hub, studs or
brake disk while removing defective bearing.
Place new bearing in a freezer for 10 minutes before installation.
To ease the assembly of the bearing, it is possible
to heat the wheel hub at 212°F (100°C), 30 minutes in oven.
 WARNING
Clean all grease, outside and inside, from
housing before putting in oven.
06-02-2
VMR2004_103_06_02A.FM
Section 06 DRIVE TRAIN
Subsection 02 (FRONT DRIVE)
Place hub in a press, make sure inner sleeve is in
place, then carefully press new ball bearing in
place.
3
3
2
1
V06H0OA
V06H0NA
1
2
1. Hub
2. Ball bearing
3. Inner sleeve
1. Wear ring
2. Ball bearing
3. Inner sleeve
The wear ring no. 5 must press into a dry bore.
Use brake cleaner to make sure the bore is free of
grease where the seal goes.
CAUTION: If the seal is pressed into a slippery
bore, it will misalign or pop out when the vehicle will be running, which will lead to a bearing
failure.
The wear ring no. 5 l must press into a dry bore.
Use brake cleaner to make sure the bore is free of
grease where the seal goes.
CAUTION: If the seal is pressed into a slippery
bore, it will misalign or pop out when the vehicle will be running, which will lead to a bearing
failure.
Inner ball bearing replacement
Remove and discard wear ring.
Offset inner sleeve no. 8. Using a hammer and a
punch, eject defective bearing.
NOTE: Be careful not to damage hub, studs or
brake disk while removing defective bearing.
Place new bearing in a freezer for 10 minutes before installation.
To ease the assembly of bearing, it is possible to
heat the wheel hub at 212°F (100°C), 30 minutes
in oven.
Installation
For installation, reverse the removal procedure.
Pay attention to the following details.
Apply synthetic grease (P/N 293 550 019) in the gap
between wear ring no. 5 and inner ball bearing.
1
 WARNING
Clean all grease, outside and inside, from
housing before putting in oven.
Place hub in a press, make sure inner sleeve is in
place, then carefully press new ball bearing in
place.
Using the press, carefully install a new wear ring.
2
V06H0PA
1. Wear ring
2. Synthetic grease
VMR2004_103_06_02A.FM
06-02-3
Section 06 DRIVE TRAIN
Subsection 02 (FRONT DRIVE)
Install wheel hub no. 6.
Put the bushing in place.
Put the wheel hub nut and tighten.
Install new cotter pin. Both ends of cotter pin must
be folded.
Install both front wheels.
Put vehicle back on the ground.
06-02-4
VMR2004_103_06_02A.FM
Section 06 DRIVE TRAIN
Subsection 03 (REAR AXLE)
REAR AXLE
0
23
24
21
22
25
1
4
Loctite 277
2
18
16
20
17
15
29
27
43 N•m
(32 lbf•ft)
17
28
27
19
18
29
26
13
16
9
3
12
140 N•m
(103 lbf•ft)
Synthetic grease
5
14
11
135 N•m
(100 lbf•ft) 10
8
6
V06H0KS
VMR2004_103_06_03A.FM
7
9
70 N•m
(52 lbf•ft)
06-03-1
Section 06 DRIVE TRAIN
Subsection 03 (REAR AXLE)
GENERAL
Lubrication and Cleaning
During assembly/installation, use torque values
and service products as in the exploded view.
Clean threads before applying threadlocker.Refer
to SELF-LOCKING FASTENERS and LOCTITE APPLICATION at the beginning of this manual for
complete procedure.
CAUTION: Never wash the chain with a high pressure washer or gasoline. Damage to the O-ring
will result, causing premature wear and drive
chain failure.
Clean the side surfaces of the chain with a dry cloth.
NOTE: Do not brush chain.
Lubricate only with an approved O-ring chain lubricant. Other commercial chain lubricants may contain solvent which could damage the O-rings.
 WARNING
Torque wrench tightening specifications
must strictly be adhered to.
Locking devices (ex.: locking tabs, elastic stop
nuts, self-locking fasteners, cotter pin, etc.)
must be installed or replaced with new ones
where specified. If the efficiency of a locking
device is impaired, it must be renewed.
CAUTION: During installation, make sure every
part is free from old grease and dirt. This allows
for a clean re-assembly and will avoid premature wear caused by dirt contamination.
After each job, ride the vehicle for a few minutes
and make sure the job is successful; i.e. axle is not
loose, chain is not rubbing on any part or making
noise, rear brake operates correctly, etc.
Adjustment
NOTE: Never adjust drive chain no. 1 with the driver seated on the vehicle. Remove all load on vehicle.
Select a level surface and set transmission to
NEUTRAL.
Loosen chain tensioner lock bolts no. 2.
DRIVE CHAIN
Adjust and lubricate drive chain no. 1 before each
use.
 WARNING
Place ignition switch to OFF before check, adjust or lubricate drive chain.
V06H02A
1
1. Chain tensioner lock bolts
Insert adjuster lock through sprocket hub no. 3
and into chain tensioner no. 4.
CAUTION: Never operate this vehicle with the
drive chain too loose or too tight as severe damage to the drive components can occur.
Inspection
This ATV is equipped with O-ring and permanently
greased sealed bearings. Before operating the vehicle, always inspect the drive chain.
Check the free play of drive chain and adjust if necessary.
Check for damage or missing O-ring or rollers.
06-03-2
VMR2004_103_06_03A.FM
Section 06 DRIVE TRAIN
Subsection 03 (REAR AXLE)
A
V02H01A
A. 404 mm (15-29/32 in)
CAUTION: Replace chain no. 1, engine sprocket and rear sprocket no. 5 together to prevent
rapid chain and sprockets wear. Install a new
tab washer each time the engine sprocket is removed.
V06H03A
1.
2.
3.
4.
4
2
3
1
Drive chain
Adjuster lock
Sprocket hub
Chain tensioner
Adjust chain deflection by slowly moving the ATV
forward so any slack that may have previously
been on the lower part of the chain is now on top.
The bottom part of the chain should be tight during
adjustment.
The deflection should be between 20 and 30 mm
(3/4 and 1-3/16 in).
REAR WHEEL HUB
Removal
Lift rear of vehicle and install jack stands under the
frame to support the rear of vehicle off the ground.
Remove rear wheel.
NOTE: Use the same procedure for both wheel
hubs.
Apply rear brake.
Remove rubber cap no. 6.
Remove cotter pin no. 7 and unscrew elastic nut
no. 8. Discard the cotter pin.
Remove washer no. 9 and the O-ring no. 10.
V06H06A
Turn the axle forward to increase or backwards to
decrease chain free play.
Tighten the chain tensioner lock bolts to 43 N•m
(32 lbf•ft).
CAUTION: Never operate this vehicle with the
drive chain too loose or too tight as severe damage to the drive components can occur.
When the adjustment is done, repeat the above
procedure to check the deflection several times
on different spots of the chain.
Replacement
With the chain installed on vehicle, measure the
distance between a span of 13 links from pin center to pin center. Change drive chain if the distance
exceeds the service limit.
VMR2004_103_06_03A.FM
V06H0DA
3
2
1
1. Cotter pin
2. Elastic nut
3. Rear wheel hub
Pull out wheel hub no. 11.
Inspection
Check wheel hub for cracks splines wear or other
damage. Change if necessary.
Check O-ring for damage. If so, change it.
06-03-3
Section 06 DRIVE TRAIN
Subsection 03 (REAR AXLE)
Installation
For installation, reverse the removal procedure.
Pay attention to the following details.
Apply synthetic grease (P/N 293 550 019) on
splines.
Install wheel hub no. 11.
Put the O-ring in place.
Put on the wheel hub nut no. 8 and tighten.
Release rear brake.
Install new cotter pin. Both ends of cotter pin must
be folded.
Install rubber cap.
Install rear wheel.
Put vehicle back on the ground.
With no driver on vehicle, adjust chain tension.
Tighten the chain tensioner lock bolts.
REAR SPROCKET AND HUB
Removal
1
V06H0AA
1. Locking nuts
Remove LH rear wheel and wheel hub.
Pull out the rear axle no. 13 with rear sprocket
no. 5 and rear sprocket hub no. 3 from drive chain
tensioner no. 4.
Lift rear of vehicle and install jack stands under the
frame to support the rear of vehicle off the ground.
Remove RH rear wheel and wheel hub no. 11.
Remove drive chain no. 1.
V06H0BA
1.
2.
3.
4.
V06H09A
1
1. Remove chain
Unscrew locking nuts no. 12 by using 51 mm (2 in)
crowfoot (P/N 529 035 884) and 51 mm (2 in) open
wrench (P/N 529 035 866).
06-03-4
2
1
3
4
Rear axle
Chain tensioner
Rear sprocket
Rear sprocket hub
Rear Sprocket Removal
Unscrew the bolts no. 14 and remove rear sprocket from rear sprocket hub no. 3.
Rear Sprocket Hub Removal
Push down the rear sprocket hub no. 3 on rear
axle to get access of retainer ring no. 15.
VMR2004_103_06_03A.FM
Section 06 DRIVE TRAIN
Subsection 03 (REAR AXLE)
Installation
For installation, reverse the removal procedure.
1
REAR AXLE
Removal
Remove retainer ring no. 15 and pull out the rear
sprocket no. 5 out with rear sprocket hub no. 3.
Lift rear of vehicle and install jack stands under the
frame to support the rear of vehicle out off the
ground.
Remove rear wheels.
Remove the LH and RH wheel hubs no. 11.
Apply rear brake.
Remove locking nuts no. 12.
Unscrew the chain tensioner lock bolts no. 2.
Release rear brake.
Install adjuster lock and release drive chain tension.
Remove drive chain from rear sprocket.
Slide out the axle from the right side of the chain
tensioner no. 4. If the vehicle was used with failed
bearings, many parts around the bearing area may
be damaged. It is possible that the axle will not slide
out easily if the bearings are seized on it.
Inspection
Inspection
Check the rear axle, sprocket and hub for distortion,
excessive wear or other damages.
Check axle for bending, torsion or other damage.
Change if necessary.
Check axle for rust. Rust indicates a possible damage to axle. Change axle if necessary.
If bearings no. 16 are seized on the axle, the axle
must be replaced or its surface cleaned. Bearings
must still have a slide fit on the axle, otherwise it
will result in a faulty re-assembly and a failure may
occur. Bearing races on the axle must be in good
condition.
If the sprocket hub no. 3 has been damaged, replace
it also.
If wear sleeves no. 17 are damaged replace them.
V06H0CA
1. Retainer ring
1
2
Installation
V02H02A
1. Good
2. Replace
CAUTION: Replace chain, engine sprocket and
rear sprocket together to prevent rapid chain
and sprockets wear. Install a new tab washer
each time the engine sprocket is removed.
VMR2004_103_06_03A.FM
Insert the axle assembly into the swing arm from
the right side.
Apply rear brake.
Apply Loctite 277 on locking nut threads then install them.
Using or open wrench (P/N 529 035 866) and a crow
foot (P/N 529 035 884), torque each nut to 140 N•m
(103 lbf•ft).
06-03-5
Section 06 DRIVE TRAIN
Subsection 03 (REAR AXLE)
Apply synthetic grease (P/N 293 550 019) on axle
splines.
Install the rear wheel hubs. See the procedure
above.
Release rear brake.
Install both rear wheels.
Put vehicle back on the ground.
2
CHAIN TENSIONER
Removal
Remove the rear axle.
Slide out the chain tensioner no. 4 from the left side
of the swing arm.
NOTE: To pull the chain tensioner out, align the
protrusion with the swing arm groove.
V06H0FA
3
1
1. Chain tensioner
2. Swing arm
3. Pry bar
Inspection
Look at the chain tensioner for damage. The bore
must be free of scratches in order to receive new
bearings and seals.
Installation
Installation takes place in the reverse order of removal.
Carefully slide the chain tensioner over the axle and
seat it against the sprocket hub; the 3 hole side of
the chain tensioner goes toward the right side.
NOTE: Make sure it is fully seated.
Install all other parts.
2
V06H0EA
1
1. Chain tensioner protrusion
2. Swing arm groove
Dirt inside the swing arm may cause resistance during removal procedure. Use a soft tool to hammer
out the chain tensioner if required.
Use pry bar to open the swing arm groove to push
the chain tensioner out from the swing arm.
06-03-6
Adjustment
Refer to DRIVE CHAIN at the beginning of this
section for proper chain tension adjustment.
CHAIN TENSIONER BEARINGS
Inspection
The rear axle should turn smoothly and quietly inside chain tensioner. If not, change the bearings.
If bearings no. 16 are seized on the axle, the axle
must be replaced or its surface cleaned. Bearings
must still have a slide fit on the axle, otherwise it
will result in a faulty re-assembly and a failure may
occur. Bearing races on the axle must be in good
condition.
VMR2004_103_06_03A.FM
Section 06 DRIVE TRAIN
Subsection 03 (REAR AXLE)
Removal
Press the bearing into the chain tensioner.
NOTE: Bearings and seals must be replaced if removed.
Remove O-ring no. 18.
Pry out drive axle seals no. 19. Be careful not to
damage seal bore or chain tensioner.
Use a punch and drive bearings cup outward from
opposite end of housing.
V06H0HA
The seal must press into a dry bore. Use brake
cleaner to make sure the bore is free of grease
where the seal goes.
CAUTION: If the seal is pressed into a slippery
bore, it will misalign or pop out when the vehicle will be running, which will lead to bearing
failure.
Press the seal no. 19 in place. Properly installed,
it is flush with the edge of the chain tensioner.
Install all other parts.
SLIDER-SHOE
V06H0GA
Removal
Installation
Place new bearings in a freezer for 10 minutes before installation.
If removed, clean sleeve no. 20 from dirt and grease,
then also place it in the freezer for 10 minutes.
To ease the assembly of bearings, it is possible to
heat the chain tensioner at 212°F (100°C), 30 minutes in oven.
Remove rear axle.
Remove swing arm. Refer to REAR SUSPENSION.
Drill rivets no. 21 and remove slider-shoe no. 22.
Installation
Installation takes place in the reverse order of removal.
 WARNING
Clean all grease, outside and inside, from
housing before putting in oven.
Place spacer no. 20 into chain tensioner bore.
VMR2004_103_06_03A.FM
06-03-7
Section 06 DRIVE TRAIN
Subsection 03 (REAR AXLE)
CHAIN GUIDE
Removal
Remove RH footrest (refer to BODY).
Remove rear brake caliper and disc (refer to
BRAKE).
Remove chain guide no. 23 and spacers no. 24.
Installation
For installation, reverse the removal procedure.
CHAIN ROLLER
Removal
Unscrew bolt no. 25 retaining the chain roller
no. 26.
Remove the chain roller with ball bearings no. 27,
bushing no. 28 and spacer no. 29.
Inspection
Replace any broken, worn or defective part.
Installation
For installation, reverse the removal procedure.
06-03-8
VMR2004_103_06_03A.FM
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