2004 Arctic Cat ATVs factory service and repair manual, Page 85Get this manual
SECONDARY GEARS I NOTE: When checking and correcting secondary gear backlash and tooth contact, the universal joint must be secured to the front shaft or false measurements will occur
2Clean 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 assembly
Checking Backlash
INOTE: The rear shaft and bevel gear must be removed for this procedureAlso, always start with the original shims on the rear shaft
5Rotate the secondary driven bevel gear several revolutions in both directions6Examine the tooth contact pattern in the dve and compare the pattern to the ifiustrationsIncorrect (contact at tooth top)
1Place the left-side crankcase cover onto the left-side crankcase half to prevent mnout of the secondary transmission output shaft2Install the secondary driven output shaft assembly onto the crankcase
3Mount the indicator tip of the dial indicator on the secondary driven bevel gear4While rocking the driven bevel gear back and forth, note the maximum backlash reading on the gauge