SECTION 19 – UNITIZED TRANSAXLE: 850 GASOLINE VEHICLE

SECTION 19 – UNITIZED TRANSAXLE: 850 GASOLINE VEHICLE
19
SECTION 19 – UNITIZED TRANSAXLE: 850
GASOLINE VEHICLE
ý DANGER
• See General Warning on page 1-1.
ý WARNING
• See General Warning on page 1-1.
GENERAL INFORMATION
Shifter Lever
A shifter lever, connected to a shifter arm, is used to change the gears to one of three shift positions: FORWARD (F), NEUTRAL (N), or REVERSE (R) (Figure 19-1, Page 19-1). Bring the vehicle to a complete stop
before changing FORWARD or REVERSE direction.
Governor System
The governor system regulates vehicle ground speed. It is mounted inside the unitized transaxle and is driven
by transaxle gears. If any of the governor linkages are removed in order to service other components, readjustment of the governor linkage is required. See Governor Cable Installation and Adjustment on
page 16-9.
Unitized Transaxle Service
The unitized transaxle is extremely durable and should require very little service under normal operating conditions. The only service required is to maintain proper lubricant level. See Periodic Lubrication Schedules,
Section 10, Page 10-4.
C l u bC a r
R
N
F
Figure 19-1 Shifter Positions (Top View)
Figure 19-2 Lubricant Level (should be level with bottom of hole) and Drain Plug
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Page 19-1
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UNITIZED TRANSAXLE: 850 GASOLINE VEHICLE
Axle Shaft
Tools Required For This Section
Hydraulic floor jack (or chain hoist)
Torque wrench, 3/8-in. drive
1/2-in. combination wrench
Jack stands (2) (one ton capacity)
3/8-in. socket, 3/8-in. drive
9/16-in. combination wrench
Standard slip joint pliers
7/16-in. socket, 3/8-in. drive
Small flat blade screwdriver
External snap ring pliers (.047-in. tip)
1/2-in. socket, 3/8-in. drive
Medium flat blade screwdrivers (2)
90° Internal snap ring pliers (.090-in. tip)
9/16-in. socket, 3/8-in. drive
No. 2 phillips-head screwdriver
16-in. rolling head prybar
5/8-in. socket, 3/8- in. drive
1/4-in. nut driver
Plastic or rubber mallet
Axle seal tool (CCI P/N 1014162)
5/16-in. nut driver
Ratchet wrench, 3/8-in. drive
7/16-in. combination wrench
LUBRICATION
There are two oil port plugs located on the right (driven clutch) side of the unitized transaxle (Figure 19-2,
Page 19-1). When the vehicle is on a level surface, use the upper plug as a lubricant level indicator. Lubricant
level should be even with the bottom of level indicator hole. Use the lower plug for draining. When draining
lubricant, remove both plugs to allow the lubricant to drain faster. Clean and reinstall the drain plug and gasket
before filling the transaxle with new lubricant. Use a funnel when filling the transaxle through the lubricant
level indicator hole. Fill with 27 oz. (0.8 liter) 80-90 WT. API class GL or 80-90 WT. AGMA class 5 EP gear
lubricant (or until lubricant begins to run out of the level indicator hole). Tighten the plug to 20 ft-lb (27.1 N·m).
AXLE SHAFT
See General Warning on page 1-1.
Removal of the unitized transaxle is not required for servicing or replacing axle shafts, axle bearings, or axle
shaft oil seals. If the unitized transaxle is to be removed from the vehicle, do not remove the wheels, axle
shafts, or axle tubes first. Instructions for removing the unitized transaxle from the vehicle begin on page 19-6.
AXLE SHAFT AND OIL SEAL REMOVAL
1. Turn the key switch to the OFF position and remove the key, place the Forward/Reverse handle in the
NEUTRAL position, and chock the wheels.
2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in
General Warning on page 1-2.
3. Loosen the lug nuts on the wheel to be removed.
4. Place chocks at the front wheels and lift the rear of the vehicle with a floor jack. Then place jack stands
under the axle tubes to support the vehicle. See WARNING “Lift only one end of the vehicle...” in
General Warning, Section 1, Page 1-1.
5. Remove the rear wheel and brake drum.
6. Use 90° internal snap ring pliers (0.090-in. tip) to remove internal retaining ring (1) from axle tube
(Figure 19-3, Page 19-3).
7. Carefully pull the axle shaft (2) straight out of the axle tube (Figure 19-3, Page 19-3).
Page 19-2
2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual
UNITIZED TRANSAXLE: 850 GASOLINE VEHICLE
Axle Shaft
2
1
Figure 19-3 Retaining Ring
8. Position a 16-inch (40 cm) rolling head prybar (Figure 19-4, Page 19-3) under the inside lip of the seal
and pull the oil seal out (Figure 19-5, Page 19-3). See following CAUTION.
ý CAUTION
• Do not scar or damage the inside surfaces of the tube when removing the oil seal. A damaged
tube might have to be replaced.
Figure 19-4 Rolling Head Prybar
Figure 19-5 Seal Lip
9. Inspect the axle shaft assembly to be sure the bearing (71) and collar (73) have not slipped and are still
seated against the shoulder on the axle shaft (Figure 19-6, Page 19-4).
10. Inspect the bearing. If the bearing is damaged or worn, replace it.
AXLE BEARING
Axle Bearing Removal
1. Use external retaining ring pliers (0.047-inch tip) to remove the retaining ring (74). Place a bearing puller
wedge attachment (CCI P/N 1012812) on the axle shaft between the wheel mounting flange and the
bearing (Figure 19-6, Page 19-4). See also Figure 19-7, Page 19-6. See following CAUTION.
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UNITIZED TRANSAXLE: 850 GASOLINE VEHICLE
Axle Shaft
ý CAUTION
• Do not tighten the bearing puller wedge attachment against the axle shaft. This could damage
the axle shaft when pressing the bearing and collar off.
2. Press the bearing (71) and collar (73) off together (Figure 19-6, Page 19-4). See also Figure 19-7,
Page 19-6. See following NOTE.
NOTE: It may be necessary to heat the collar to remove it.
Do not remove the large axle retaining ring (70) from the axle (Figure 19-6, Page 19-4). Since the
inner diameter of the retaining ring (70) is smaller than the outer diameter of the bearing (71), the
ring must be in place on the axle before a new bearing and collar are pressed on.
75
74
71
72
72
73
70
67
76
68
74
71
73
70
73
74
71
70
Figure 19-6 Differential Gear Case and Axle Tubes
Page 19-4
2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual
UNITIZED TRANSAXLE: 850 GASOLINE VEHICLE
Axle Shaft
Axle Bearing Installation
1. Ensure that the retaining ring (70) is loosely placed on the axle shaft. See preceding NOTE.
2. Install a new axle bearing (71) on axle (67 or 68). Push bearing onto axle until bearing is flush against
axle shoulder (Figure 19-6, Page 19-4).
3. Apply two drops of Loctite 271® to inside of the collar. See following CAUTION.
ý CAUTION
• Apply Loctite 271 to the inside of the collar only, not to the shaft, so that the Loctite will be
pushed away from the bearing as the collar and bearing are pressed on. If Loctite gets on or in
the bearing, the bearing must be replaced.
• The collar should be removed no more than two times. If a collar is removed a third time, the
shaft and collar will not fit properly.
4. Place a new sealed bearing (71) on shaft (67 or 68) (Figure 19-6, Page 19-4).
5. Install collar (73) onto axle shaft. Place axle assembly on bearing puller wedge attachment and press collar onto axle.
6. Place the bearing puller wedge attachment against collar and press both bearing and collar onto shaft.
See following CAUTION.
ý CAUTION
• If the bearing was removed from the shaft, replace it with a new one.
• Do not tighten the bearing puller wedge attachment against the axle shaft. This could damage
the axle shaft when the bearing and collar are pressed on.
7. Use external snap ring pliers (0.047-in. tip) to install collar retaining ring (74) (Figure 19-6, Page 19-4).
AXLE SHAFT INSTALLATION
1. Clean bearing and seal seats in axle tube (75 or 76) (Figure 19-6, Page 19-4).
2. Place a new oil seal (72) in axle tube with seal lip facing inside of the axle tube (Figure 19-6, Page 19-4).
Use an axle seal tool (CCI P/N 1012811) to press it in until it seats firmly in position (Figure 19-8,
Page 19-6). See following NOTE.
NOTE: The new seal can be installed by tapping the axle seal tool with a mallet.
ý CAUTION
• Clean any residual oil from the exposed end of the axle shaft and from the oil seal area prior to
installing the axle shaft.
3. Clean the axle shaft and splines and then insert the shaft, splined end first, through the seal and into the
axle tube. Be careful not to damage the seal. Then advance the shaft through the inner bearing and
rotate it to align the shaft splines with the splined bore of the differential side gear. Continue advancing
the shaft until the bearing seats against the axle tube shoulder.
4. Install the bearing retaining ring (70) in the axle tube (Figure 19-6, Page 19-4). See also Figure 19-3,
Page 19-3.
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UNITIZED TRANSAXLE: 850 GASOLINE VEHICLE
Unitized Transaxle Removal
5. Place a 1/4 to 3/8-inch (6-10 mm) diameter rod against the retaining ring and tap lightly at four to five
locations to ensure it is properly seated. See following WARNING.
ý WARNING
• Be sure bearing retaining ring is properly seated in its groove. If ring is not properly installed,
the axle assembly will separate from the transaxle and damage the axle assembly and other
components. Loss of vehicle control could result in severe personal injury or death.
Figure 19-7 Press Bearing and Collar From Shaft
Using Bearing Puller Wedge Attachment
Figure 19-8 Axle Seal and Seal Tool
UNITIZED TRANSAXLE REMOVAL
See General Warning on page 1-1.
1. Turn the key switch to the OFF position and remove the key, and place the Forward/Reverse handle in
the NEUTRAL position.
2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in
General Warning on page 1-2.
3. Close the fuel shut-off valve on fuel tank (Figure 16-18, Page 16-25 or Figure 16-19, Page 16-25).
4. Detach all wires, hoses, etc. connecting the powertrain to the vehicle.
4.1. Disconnect the carburetor vent tube from the carburetor (Figure 19-9, Page 19-7).
4.2. Disconnect the air intake hose from the carburetor (Figure 19-10, Page 19-7).
Page 19-6
2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual
UNITIZED TRANSAXLE: 850 GASOLINE VEHICLE
Figure 19-9 Fuel Vent Tube
Unitized Transaxle Removal
Figure 19-10 Air Intake Hose
4.3. Disconnect impulse line from fuel pump (Figure 19-11, Page 19-7).
4.4. Loosen the hose clamp and then disconnect the fuel line from the carburetor. To prevent spilling
fuel, the disconnected end of the line can be plugged with a 1/4-inch bolt (Figure 19-12,
Page 19-7).
Figure 19-11 Impulse Line
Figure 19-12 Fuel Line
4.5. Remove the cover from the electrical component box. Then loosen the hardware securing the
accelerator cable to the box. Disconnect the cable from the actuator cam and remove it from the
box (Figure 19-13, Page 19-8).
4.6. Remove retaining nut and disconnect the engine ground wire from the oil filler tube mounting
bracket (Figure 19-14, Page 19-8).
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UNITIZED TRANSAXLE: 850 GASOLINE VEHICLE
Unitized Transaxle Removal
Figure 19-13 Throttle Cable and Retaining Nuts (Top
View)
Figure 19-14 Engine Ground Wire and Retaining Nut
4.7. Loosen nuts securing shifter cable to shifter cable mounting bracket. Then disconnect the shifter
cable rod end from the shifter arm on the unitized transaxle and remove the cable from the cable
mounting bracket (Figure 19-15, Page 19-8).
4.8. Mark for identification and then disconnect the 6-gauge white wire (F2 post), 6-gauge black ground
wire (A2 post), and 16-gauge yellow wire (DF post) from starter/generator (Figure 19-16,
Page 19-8).
1
2
1
F2
19
3
F2
DF
2
Figure 19-15 Shifter Cable (Top View)
1. Loosen nuts. 2. Pull spring release back to remove shifter
cable from lever.
Figure 19-16 Generator Wires
1. Yellow Wire 2. White Wire 3. Ground Wire at A2 Terminal
4.9. Disconnect the engine oil level sensor wire (18-gauge yellow) at the connector just to the rear of the
starter/generator) (Figure 19-17, Page 19-9).
4.10. Disconnect the engine kill switch wire (18-gauge white/black) from the bullet connector at the lower
right front of the engine (Figure 19-18, Page 19-9).
4.11. Cut away the wire ties securing the engine kill wire at the lower right front of the engine (below the
exhaust header), the wire harness at the governor cable bracket, and the wire harness to the plate
beneath the muffler.
Page 19-8
2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual
UNITIZED TRANSAXLE: 850 GASOLINE VEHICLE
Figure 19-17 Oil Level Sensor Jumper Wire
Unitized Transaxle Removal
Figure 19-18 Ignition Kill Wire
5. Disconnect the brake cables.
5.1. Remove bow tie pins (1), brake cable clevis pins (2), and E-clips (3) (Figure 19-19, Page 19-9).
5.2. Remove the cable from the cable support bracket (Figure 19-19, Page 19-9).
2
4
3
1
Figure 19-19 Brake Cable (Rear View)
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UNITIZED TRANSAXLE: 850 GASOLINE VEHICLE
Unitized Transaxle Removal
6. Remove the lower shock mounting hardware from both rear shocks (Figure 19-20, Page 19-10).
7. Position a floor jack under the vehicle frame crossmember or trailer hitch mount (Figure 19-21,
Page 19-10).
Figure 19-20 Shock Absorbers
Figure 19-21 Floor Jack Positioned Under
Hitch Bracket
8. Raise vehicle just enough to relieve tension from leaf springs, then remove the bolts securing the leaf
springs to the shackles (Figure 19-22, Page 19-10).
9. Remove the bolts securing the leaf springs to their front mounts (Figure 19-23, Page 19-10).
Figure 19-22 Rear Shackles
Figure 19-23 Spring Retainer Bolts
10. Continue raising vehicle until frame or trailer hitch is higher than the top of the unitized transmission
(enough to allow transaxle and engine to be rolled under and out of vehicle) (Figure 19-24, Page 19-11).
Page 19-10
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UNITIZED TRANSAXLE: 850 GASOLINE VEHICLE
Unitized Transaxle Removal
11. Position jack stands, adjusted to support the vehicle at this height, under the frame crossmember
between the leaf spring mounts and side stringers, just forward of each rear wheel. Lower the floor jack
to allow the jack stands to support the vehicle (Figure 19-25, Page 19-11).
Figure 19-24 Raise Vehicle
Figure 19-25 Position Jack Stands On Both Sides of
Frame
12. Pull the floor jack from beneath the vehicle and move it away.
13. Carefully lift the snubber out of the snubber bracket in the vehicle frame and lower it to the floor (Figure 19-26,
Page 19-11). The powertrain should be completely disconnected from the vehicle and resting on the floor.
14. Grasp the ends of the leaf springs at the rear of the vehicle and roll the powertrain out from under the vehicle
(Figure 19-27, Page 19-11).
Figure 19-26 Snubber and Bracket
Figure 19-27 Remove Powertrain
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UNITIZED TRANSAXLE: 850 GASOLINE VEHICLE
Unitized Transaxle Removal
15. Place blocks under the engine pan so they will completely support the engine and keep it level to the
floor (Figure 19-28, Page 19-12). See following NOTE.
NOTE: Place the blocks so they will support the engine when the transaxle is detached and moved away
from the engine.
16. Remove the drive belt.
16.1. Grasp belt midway between drive and driven clutch and pull up on belt to force the driven clutch
sheaves apart. Roll the belt counterclockwise while pulling it off driven clutch (Figure 19-29,
Page 19-12).
6 in. (15.24 cm)
Figure 19-28 Position Powertrain on Wood Blocks
Figure 19-29 Remove Drive Belt
17. Remove the driven clutch retaining bolt and remove the driven clutch from the unitized transaxle
(Figure 19-30, Page 19-12).
18. Loosen, but do not remove, the governor arm retaining bolt (1) (Figure 19-31, Page 19-12). Remove the
governor arm from the shaft. Do not disconnect cables.
1
Figure 19-30 Driven Clutch
Page 19-12
Figure 19-31 Governor Arm
2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual
UNITIZED TRANSAXLE: 850 GASOLINE VEHICLE
Unitized Transaxle Removal
19. Remove screws (1) securing the governor cable bracket to transaxle (Figure 19-32, Page 19-13).
20. Remove screws (1) securing the accelerator cable bracket to transaxle (Figure 19-33, Page 19-13).
1
1
Figure 19-32 Governor Cable Bracket
Figure 19-33 Accelerator Cable Bracket
21. Remove the six bolts mounting the unitized transaxle to the engine.
21.1. Remove four transaxle mounting bolts (one at each corner of the transaxle mounting plate)
(Figure 19-34, Page 19-13).
21.2. Remove two middle transaxle mounting nuts from the engine block studs.
22. Remove leaf springs, wheels and brake assemblies from the transaxle.
Figure 19-34 Transaxle Mounting
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UNITIZED TRANSAXLE: 850 GASOLINE VEHICLE
Unitized Transaxle Installation
UNITIZED TRANSAXLE INSTALLATION
See General Warning on page 1-1.
1. Install the wheels. See Wheel Installation, Section 8, Page 8-1.
2. Install the leaf springs. See Leaf Spring Installation – All Vehicles, Section 9, Page 9-4.
3. Position the transaxle mounting plate on the two mounting studs at the rear of the engine, and then install
the two mounting nuts finger tight (Figure 19-35, Page 19-14).
4. Install the remaining four mounting bolts and four nuts (one bolt and nut at each corner of the mounting
plate) finger tight.
5. Tighten the four corner nuts (with bolts) to 30 ft-lb (40.7 N·m). Tighten the two center nuts (on the engine
block studs) to 17 ft-lb (23.1 N·m) (Figure 19-35, Page 19-14).
6. Install the accelerator cable bracket on transaxle case. Tighten the mounting screws to 134 in-lb (15.1
N·m) (Figure 19-33, Page 19-13).
Figure 19-35 Transaxle Mounting
Figure 19-36 Governor Arm
7. Install the governor cable bracket on transaxle case. Tighten the mounting screws to 134 in-lb (15.1 N·m)
(Figure 19-32, Page 19-13).
8. Install governor lever arm on governor shaft (Figure 19-36, Page 19-14).
8.1. With the governor lever arm loose on the governor shaft, turn the governor arm shaft counterclockwise until it stops. Then pull the governor lever arm rearward until the carburetor throttle is in the
“wide open throttle” (WOT) position (Figure 19-36, Page 19-14).
8.2. While holding the arm and shaft in the fully counterclockwise position, tighten the governor arm
lever nut to 35 in-lb (4.0 N·m) (Figure 19-36, Page 19-14).
9. Install the key onto the input shaft (Figure 19-37, Page 19-15).
10. Position the driven clutch on the transaxle input shaft and install the washer (yellow side facing out) and
mounting bolt. Tighten the mounting bolt to 14 ft-lb (19.0 N·m) (Figure 19-37, Page 19-15).
11. Install the drive belt. See Drive Belt Installation, Section 20, Page 20-3.
Page 19-14
2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual
UNITIZED TRANSAXLE: 850 GASOLINE VEHICLE
Unitized Transaxle Installation
12. Remove the blocks from under the engine and roll the powertrain into position under the vehicle. Then
lift the front of the powertrain and place the snubber into the snubber bracket in the vehicle frame
(Figure 19-38, Page 19-15).
Clu
Figure 19-37 Driven Clutch and Key
bC
ar
Figure 19-38 Snubber and Bracket
13. Position the floor jack under the rear frame crossmember and raise the jack high enough to support the vehicle (Figure 19-39, Page 19-15). Make sure the vehicle is stable on the jack, then remove the jack stands.
14. After the jack stands are removed, lower the vehicle to approximately its normal height. Position the leaf
springs in the front spring mounts and install the bolts and lock nuts. Tighten to 15 ft-lb (20.3 N·m).
15. Adjust the vehicle height with the floor jack to position the leaf springs for mounting in the shackles. Install
the mounting bolts, and lock nuts (Figure 19-40, Page 19-15).
Figure 19-39 Leaf Springs
Figure 19-40 Leaf Springs and Shackles
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UNITIZED TRANSAXLE: 850 GASOLINE VEHICLE
Unitized Transaxle Installation
16. Position shocks in the shock mounts and install cushions, mounting washers and nuts (Figure 19-41,
Page 19-16). Tighten nuts until cushions expand to be the same diameter as the mounting washers.
17. Connect brake cables. See Brake Cable Installation, Section 6, Page 6-11.
18. Connect the engine kill switch wire (18-gauge white/black) to the bullet connector at the lower right front
of the engine (Figure 19-42, Page 19-16).
19. Install three wire ties to secure the engine kill wire to the accelerator cable where they both route together
on the passenger side of the engine.
Figure 19-41 Shock Absorber
Figure 19-42 Ignition Kill Wire
20. Connect the oil level sensor wire (18-gauge yellow) to the jumper wire (Figure 19-43, Page 19-16).
21. Connect the 6-gauge white wire to the F2 post, the 6-gauge black ground wire to the A2 post and tighten
both wires to 48 in-lb (5.4 N·m). Connect the 16-gauge yellow wire to the DF post on the starter/generator
and tighten to 30 in-lb (3.4 N·m) (Figure 19-44, Page 19-16).
1
2
F2
19
3
F2
DF
Figure 19-43 Oil Level Sensor Jumper wire
Figure 19-44 Starter/Generator
1. Yellow Wire 2. White Wire 3. Ground Wire at A2 Terminal
Page 19-16
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UNITIZED TRANSAXLE: 850 GASOLINE VEHICLE
Unitized Transaxle Installation
22. Position the shifter cable in the shifter cable mounting bracket on the engine and tighten the mounting
nuts to 22 ft-lb (29.8 N·m). Connect shifter cable rod end to the shifter arm (Figure 19-45, Page 19-17).
23. Attach the ground wire to the mounting screw on the oil filler tube mounting bracket and tighten to 50 inlb (5.7 N·m) (Figure 19-46, Page 19-17).
1
ar
bC
Clu
2
Figure 19-45 Shifter Cable (Top View)
Figure 19-46 Engine Ground and Retaining Nut
1. Nuts. 2. Pull spring release back to connect shifter cable to
lever.
24. Connect accelerator cable to actuator cam in the electrical box. Position the accelerator cable in the
mounting slot in the wall of the electrical box and tighten mounting nuts to 18 in-lb (2.0 N·m)
(Figure 19-47, Page 19-17). Install electrical box cover and tighten mounting screw.
25. Remove the 1/4-inch bolt from the fuel line and connect the fuel line to the carburetor and secure with
a hose clamp (Figure 19-48, Page 19-17).
TOP VIEW
RETAINING NUTS
Figure 19-47 Connect Cable to Cam and Secure with
Retaining Nuts
Figure 19-48 Connect Fuel Line
26. Connect the impulse line to the fuel pump and secure it with the hose clamp (Figure 19-49, Page 19-18).
27. Connect air intake hose to carburetor and secure hose clamp (Figure 19-50, Page 19-18).
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UNITIZED TRANSAXLE: 850 GASOLINE VEHICLE
Figure 19-49 Impulse Line
Unitized Transaxle Installation
Figure 19-50 Air Intake Hose
28. Connect carburetor vent tube to carburetor and secure with hose clamp (Figure 19-51, Page 19-18).
Figure 19-51 Carburetor Tube
29. Install transaxle drain plug and tighten to 21 ft-lb (28.5 N·m).
30. Fill transaxle with 27 oz. (0.8 liter) 80-90 Wt. API class GL-3 or 80-90 WT. AGMA class EP gear lube.
Install and tighten the level indicator hole plug to 21 ft-lb (28.5 N·m).
31. Ensure that all wiring is secured properly. See following WARNING.
ý WARNING
• If wires are removed or replaced make sure wiring and wiring harness is properly routed and
secured to vehicle frame. Failure to properly route and secure wiring could result in vehicle
malfunction, property damage or personal injury.
Page 19-18
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UNITIZED TRANSAXLE: 850 GASOLINE VEHICLE
Forward/Reverse Shifter Cable
32. Connect the spark plug wire.
33. Connect battery cables, positive (+) cable first, and tighten hardware to 144 in-lb (16 N·m) (Figure 1-1,
Page 1-3). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305) to minimize corrosion
34. Adjust the engine RPM setting. See Engine RPM Adjustment on page 16-12.
FORWARD/REVERSE SHIFTER CABLE
See General Warning on page 1-1.
If the Forward/Reverse shifter cable is damaged in any way, it must be replaced.
FORWARD/REVERSE SHIFTER CABLE REMOVAL
NOTE: Before removing cable, note cable routing and positions of wire ties or other devices securing the
cable to the vehicle. When installed, cable must be routed and secured as it was originally.
1. Turn the key switch to the OFF position and remove the key. Place the Forward/Reverse handle in the
NEUTRAL position and chock the wheels.
2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in
General Warning on page 1-2.
3. Remove the cable end socket (1) from the Forward/Reverse shifter assembly stud (2) (Figure 19-52,
Page 19-20).
4. Depress and push down on tangs (3) anchoring front of cable jacket to chassis bracket.
5. Remove the ball joint socket (4) from the shifter arm ball stud (5) on the transaxle.
6. Loosen the retaining nuts (6) anchoring rear of cable jacket to bracket (7) at starter/generator.
7. If equipped, remove wire tie(s) securing cable jacket to frame rail.
8. Remove cable (8) from the vehicle.
FORWARD/REVERSE SHIFTER CABLE INSTALLATION
1. Begin at the Forward/Reverse shifter, and route the cable (8) exactly as it was originally, to the transaxle
shifter lever.
2. Secure rear of cable jacket to bracket (7) at starter/generator with a retaining nut (6) on each side of the
bracket (Figure 19-52, Page 19-20). Tighten nuts to 22 ft-lb (29.8 N·m).
3. Feed front of cable through the chassis bracket and push the cable jacket anchor up into bracket until
tangs (3) snap into place.
4. Install the ball joint socket (4) on the shifter arm ball stud (5) on the transaxle.
5. Install the cable end socket (1) on the Forward/Reverse shifter assembly stud (2) (Figure 19-52,
Page 19-20).
6. If originally equipped, secure cable jacket to frame rail with wire tie(s).
7. Connect battery cables, positive (+) cable first, and tighten hardware to 144 in-lb (16 N·m) (Figure 1-1,
Page 1-3). Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305) to minimize corrosion.
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UNITIZED TRANSAXLE: 850 GASOLINE VEHICLE
Forward/Reverse Shifter Cable
1
2
3
9
8
7
4
6
10
5
Figure 19-52 Forward/Reverse Shifter Cable
Page 19-20
2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual
UNITIZED TRANSAXLE: 850 GASOLINE VEHICLE
Forward/Reverse Shifter Cable
FORWARD/REVERSE SHIFTER CABLE ADJUSTMENT
With the shifter lever of the unitized transaxle in the NEUTRAL position (Figure 19-53, Page 19-21), the Forward/Reverse handle (9) (Figure 19-52, Page 19-20) should align with the N position on the dash. For minor
adjustments, the nut (10) may be loosened and the ball joint socket (4) rotated to get the proper adjustment
(Figure 19-52, Page 19-20). See following CAUTION.
ý CAUTION
• Be sure threads of cable are engaged in ball joint socket at least 1/4 inch (6.35 mm). If ball
joint socket comes loose from the cable, the Forward/Reverse shifter will not operate
properly.
R
N
F
Figure 19-53 Forward/Reverse Shifter Positions
For major adjustments, the cable jacket retaining nuts (6) must be loosened and adjusted. When the cable is
properly adjusted, with the Forward/Reverse handle (9) (Figure 19-52, Page 19-20) in the NEUTRAL position, the shifter arm of the transaxle will also be in the NEUTRAL position (Figure 19-53, Page 19-21).
Tighten nuts at the transaxle to 22 ft-lb (29.8 N·m).
2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual
Page 19-21
19
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