13. DRIVE TRAIN MXU 500 IRS SERVICE INFORMATION GENERAL INSTRUCTIONS · Too little backlash is extremely destructive to the gear teeth. If a test ride following reassembly indicates this condition, stop riding immediately to minimize gear damage. · Stop riding immediately if broken gear teeth are suspected. This condition could result in the shaft drive assembly locking up, causing loss of control of the machine and possible injury to the rider. · An apparent oil leak on a new or nearly new machine may be the result of a rust-preventative coating or excessive seal lubrication. · Always clean the machine and recheck the suspected location of an apparent leakage. TORQUE VALUES Front drive gear case mounting bolt 4 kgf-m (40 Nm, 29 lbf-ft) Front propeller shaft bolt 4.5 kgf-m (45 N-m, 32.4 lbf-ft) Shifting fork shaft plug 1.5 kgf-m (15 N-m, 11 lbf-ft) Apply threebond: 1215 Front drive gear case bolt 2.3 kgf-m (23 N-m, 16.5 lbf-ft) Apply threebond: 1215 2WD/4WD shift motor mounting bolt (M8) 2.3 kgf-m (23 N-m, 16.5 lbf-ft) Apply threebond: 1215 2WD/4WD shift motor mounting bolt (M6) 1.2 kgf-m (12 N-m, 8.5 lbf-ft) Rear drive gear case mounting nut 5.5 kgf-m (55 Nm, 40 lbf-ft) Rear drive gear case bolt (M10) 5 kgf-m (49 N-m, 36 lbf-ft) Apply threebond: 1215 Rear drive gear case bolt (M8) 2.5 kgf-m (25 N-m, 19 lbf-ft) Apply threebond: 1215 SPECIAL TOOLS A120E00014 Bearing puller A120E00037 Joint yoke remover A120F00016 Drive shaft puller A120F00017 Yoke bearing puller A120F00018 Pinion gear puller A120F00026 Bearing lock nut wrench A120F00020/25 TROUBLESHOOTING 1. A pronounced hesitation movement during acceleration, deceleration, or sustained speed. (This must not be confused with engine surging or transmission characteristics.) 2. A "rolling rumble" noticeable at low speed; a high-pitched whine from front drive component or area. 3. A locked-up condition of the shaft drive train mechanism, no power transmitted from the engine to the front and /or rear wheel. · Bearing damage · Improper backlash · Gear tooth damage · Broken propeller shaft · Broken gear teeth · Seizure due to lack of lubrication · Small foreign objects lodged between the moving parts. 13-2