2003 Arctic Cat ATVs from 250cc to 500cc Service Manual, Page 225Get this manual
1If backlash measurement is less than specified, remove an existing shim, measure it, and install new thinner shim2If backlash measurement is more than specified, remove an existing shim, measure it, and install thicker shim NOTE: Continue to remove, measure, and install until backlash measurement is within toleranceNote the following chart Incorrect (contact at tooth root)
Backlash Measurement
Under 0.05 mm (0.002 in At 0.05-0.33 mm (0.002-0.013 in Over 0.33 mm (0.013 in
Shim Correction
Decrease Shim Thickness No Correction Required Increase Shim Thickness
Correct
ATV-0105
Checking Tooth Contact
NOTE: After correcting backlash of the secondary driven bevel gear, it is necessary to check tooth contactATV-0104
1Remove the secondary driven output shaft assembly from the left-side crankcase half2Clean the secondary driven bevel gear teeth of old oil and grease residue3Apply thin, even coat of machinist-layout dye to several teeth of the gear4Install the secondary driven output shaft assembly5Rotate the secondary driven bevel gear several revolutions in both directions6Examine the tooth contact pattern in the dye and compare the pattern to the illustrationsIncorrect (contact at tooth top)