Boot Replacement; Gearshift Selector - Polaris 1999 Sportsman 400 Service Manual

284
Boo t Re pla cem ent
Replace the rubber boot whenever a tear or hole is
fou nd or if the rubbe r has stall ed to deteriora te. If
the boot is damaged, it wi ll allow moisture to enter
the shift selector body a nd res ult in internal dama ge
and shilling probl em s.
I.
Rem ove the cap lim n the shill knob.
2. Remove the Torx screw securing the shill knob
to the shift se lector rod. Rem ove the shift knob.
3A. On 1996- 1999 mod el s, perfor m the follow ing:
a. Remove the upper and lower clamps securing
the rubber boot to the shill selec t rod and
cover.
b. Slide the rubber boo t up a nd off the shill se-
lector rod .
38 . On 2000 mode ls, perform the follow ing:
a. Remove the wire strap securing the rubber
boot to the shill se lec t rod and cover. Discard
the w ire strap.
b. Remove the four screws securing the rubber
boo t/cover to the lever body.
c. Sl ide the rubber boot/cover up and off the
shift se lector rod .
4. Clean off any rust or corrosion from the shin se-
lector rod where the boot attac hes.
5A. On 1996-1999 models, pe rfo rm the follow ing:
a. Set the rubb er boot nex t to the cover and note
the location of the upper clam ping area of the
bool.
b. Mark this area w ith a perma nent marking pen,
then apply RTV silicone to the rod ill this
area. Thi s ensures a watertig ht sea l when the
boo t is insta lled.
c. Slide the new rubber boo
I
o nto the shill selec-
tor rod and into position
0 11
the cover. lf ncc-
cssary, app ly a light coa t of RTV si licone
aro und the top of the boot and rod.
d. Install the lowe r clamp and tighten
it sec urely.
e. Install the upper d amp and tighten
it
sec urely.
58 . On 2000 models, perf orm the follow ing:
a. A pply a light coat of ThreeBond 12 15 gask et
scaler to the body mating surface.
b. Slide the rubber boo t/co ver down ont o the
shift
se lector
rod.
c.
Insta ll the screws. Tighte n the screws a few
turns at a tim e in a crisscross pattern
10
the
torq ue speci lica tion listed
in Table I.
d. Insta ll a new w ire strap sec uring the rubber
boot to the shift selec t rod and co ver.
C HAPT E R NI NE
6. Insta ll the shift kno b onto the shift selector rod
and push it do wn until
it
bo tto ms.
7. Insta ll the To rx screw a nd tighten sec urely.
8. Insta ll the cap on to the shill knob.
G earshift Se lecto r
(1996-1999 M odels)
Disass embly
Refer to Figure 148.
I . Rem ove the gears hift se lector as described in
this chapter.
2. Remove the cap fro m the shift knob.
3. Rem ove the Torx screw sec uring the shift kno b
to the shift se lecto r rod. Rem ove the shill knob .
4 . Place the gearshi ft selec tor body in a vise with
soft jaws.
NOTE
A" 1996-1998 models. the cover is
under spring pressure and must be
held in place while loosening the
cover scre ws.
Ttte
1999 model is not
equipped with this spring.
5. Whi le ho ldi ng o nto the cover, loosen the co ve r
screws a few turn s at a time in a crisscross patt ern .
Remove
all
screws.
6A. On
J
996- 1998 mod els, perform the following:
a. Ca refu lly pull the cover/sh ift se lector rod as-
sembly straight up and off the body to avoid
dam age to the internal gear selector switch.
b. Carefully remove the internal gear se lec to r
sw itch straight op and out of the body.
6 B. On 1999 mode ls, remove the cover/shift selec-
tor rod assem bly from the body.
7. Withdraw the w hite plastic bea rin g Clip and
springs from the body.