Jamin
posted this on April 11, 2011 11:59
The following measures are needed because of a conversion to a new bearing 0625160040 on the main shaft:
A) Bearing change on an existing engine case
On case serial number from 12 0001 to 12 0470
Remove the currently installed disk 54633015000 (1.5 mm thickness) and install a new disk 77233015000 (1.3 mm thickness/figure no. 19) with the new bearing 0625160040. Insert the disk 77233089000 (figure no. 21) between the engine case and the bearing.
If the bearing is changed on existing engine cases outside of the range listed above, please order bearing kit 77233099000 (contains the new bearing 0625160040 and the disks 77233015000 (figure no. 19), 77233088000 (figure 22) and 77233089000 (figure no. 21).Please install these as required (see diagram 1).

B) New replacement engine case
If an engine case (77230000044) from the spare parts center is used, it is already equipped with the new bearing 0625160040 and the disk (figure no.22).
Remove the disk 54633015000 (1.5 mm thickness) between the main shaft and the bearing (figure no.19) and replace it with disk 77233015000 (1.3 mm thickness) (see diagram 2) – this disk is included with the new engine case.

Due to the different sealing properties of drive plates 77233089000 and 77233088000 (which are installed between the housing and the new bearing as needed), it is beneficial to install a different restrictor 77230066000 (size 60) at the position indicated by the red arrow.
In housings that have already been modified, the restrictor only needs to be changed if functional problems (i.e. clutch drag) occur with the clutch.

Comments
Where can I find the case serial number? Thanks. Sam.
Sam,
The serial number is located on the case just below the shift lever.
» Please use the following important guidelines pertaining to the engine case production
number, located beneath the electric starter motor on both engine case halves!!!
---------------
For engine cases with a production number 12 0001 to 12 0470 use bearing shim
772 33 089 000 ( 21x41x0.2 ). For engine cases with a production number outside
of this range, use bearing shim 772 33 088 000 ( 21x42x0.2 ).
» Replace the original stop disk 1.5mm thickness (item 19 above) with the new disk
1.3mm thickness (supplied with conversion kit)
Britt Childress - Service Manager, Appalachian OffRoad Motorcycles