Output Shaft End Play Inspection And Adjustment - Polaris 1999 Sportsman 400 Service Manual

TRANSMISSION
a. Ensure that the O-ring ente rs the transmission
case wit hout dam age.
b. Slowl y rotate the pin ion gea r assemb ly (Fig-
ure 128) back and forth to ens ure the ge ars
mesh properly witho ut damage.
c. Have an assi stant slow ly rota te the front out-
put shaft whil e screw ing the front output
housing onto the tran smi ssion cas e. As gear
backla sh is reduced to zero, the shaft wi ll be-
gin to bind. At this point stop screw ing in and
back the front output housing o ut ofthe tran s-
mission case by 1/4 of a tum.
d. If none of the internal compone nts w ere re-
placed. the alignment ma rk made in Removal
Step 2, between the front outp ut housing and
the transmission case (Figu re 123) should
now be aligned .
e. Measure the output gear backlash as de-
sc ribed under Output Shaft Gear Backlash In-
spection and Adj ustment in this cha pter.
18. Clean the scaling sur faces of the tran smission
case (B , Figure 127) and the insid e surface of the
bottom access plate w ith an ae roso l part s clean er.
279
19. Apply an even coat of ThreeBond 12 15, or
equivalent , gas ket sea lant to the sealing surface of
the tran sm ission case (Fig ure 129).
20. Install the bottom access plate, bolts a nd
lockwashers (Fi gur e 130). Tight en the screws to
the torqu e spec ilicatio n listed in Table 1.
2 1. Install a new fro nt sea l into the output housing.
Press
it in
unti l it is flush with the housing.
22. Tight en the o utput ho usin g pinch bo lts (Figure
131)
sec ure ly.
Outp ut S ha ft E nd Pi a )'
Inspec tion a nd Adjustme nt
Thi s pro cedure requires the use of
a dial
indicator
and stand. It is recommended that a Polaris dealer-
ship perform this pro cedure due to the special tool s
and expert ise required .
I .
Install the shaft and inner bearing into the trans-
mission end of the fron t o utput hou sin g . Push
it
in
until it stops.
II
2. Turn the front output hou sing over and install the •
out er bear ing ontu the sha ft. Push it in until it is tull y
seated in the housing.
NOTE
Do not insta ll the origi nal shims be-
twee n the shafs and the circltp at this
time.
3. Install the circl ip onto the sha ft. It may be neces-
sary to tap the ei rclip into place. Make sure it is cor -
rectly seated in the sha ft groove.
4. Install the hou sing in a vise w ith so ft j aws so it is
secure,
Do
not overtighten as the hou sing may be
damaged.
5. Set up a dial indicator so it to uches the end of the
output sha ft.
6. Push the output shaft a ll the way into the housing
and zero the dial ind icator.
7. Slow ly pull the ou tput shaft ou t from the hou sin g
and note the readi ng without any shims .
8. Measur e the thick ness of the ex isting shims and
not e the dimension.
9. To ca lc ulate COITect end play, subtract the tota l
shim thick ness measur ed in
Step 8,
from the end
play mea sured
in
Step 7. Add or subtract shims to
ac hieve the end play spec ifica tion listed in Ta b le 2.
Rep laceme nt shims are avail able from Polaris deal-
erships in five different thickness.