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Assembling and Installing the Transfer Case

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Written by Randy Fox   
Saturday, 03 November 2007

Continuing Assembly on the Left-Side

Next, moving back to the bike's left-side, remove the nut from the middle driven shaft.

Now, install the ultra-thin O-ring onto the middle driven shaft. Then install the spacer-sleeve onto the middle driven shaft, beveled end out.

Next, engage the front drive pulley with the drive belt. Also be sure the belt is engaged with the rear pulley--at the rear wheel. Now, push the front drive pulley--with the belt still engaged--onto the middle driven shaft. Then install the middle driven gear locking-washer and nut.

Tip: You can slacken the rear wheel, if the front pulley is difficult to install.

Apply the rear brake, to hold the drive pulleys stationary. Then torque the middle driven gear nut to 61 ft-lbs. Now bend the locking-washer tab up against the side of the nut.

Tip: When my transmission recall was done, the dealership mechanic didn’t pay attention to the tab-lock washer aligning with the nut face. So I had to put the washer and nut on, torque the nut, estimate how far off the nut face was from aligning with the tab, remove the nut again, remove and reposition the tab-washer, and re-torque the nut. This is not required. I just like things to line up properly.

 
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