Transmission Case Disassembly - Polaris 1999 Sportsman 400 Service Manual

252
a. Apply a coat of antiseize to the front output
shaft splines (Figure 12) prior to installation
into the front propeller shaft (Figure
1tJ).
b. Tighten the transmi ssion mounting bolts se-
curely in the following order: front support
bracket , front support bracket upper and
lower bolts, transmission lower mounting
bolts, lower left and right tran smission frame
mounting bolts.
e. Refil l the transmission oil as described in
Chapter Three.
d. Adjust the shift rod as described in this chapter.
Transmi ssion Case Disassembly
@
CHAPTE R NINE
/
,
Refer to Figure 13.
1.
If not already drained, remove the dipstick and
drain the oil from the transmission.
2. Remove the drain plug and washer (F igure 14)
from the base of the right case half.
3. Shi ft the transmission into NEU TRA L.
4. On I999-on models. perform Ihe following:
a. Mark the front gear indicator switch with a F
(fro nt) (A, Figure 15). The switche s are dif-
ferent and must be reinstalled in the correct
location.
b. Remove the mounting screws and remove
both gear indicatorswitches (A andB, Figure
15)
from
the top of the transmission case.
5. Set the transmission on wooden blocks with the
left side facing up.
6A. On 1996
models,
remove the perimeter bolts,
washers and self-locking nuts sec-uring the trans-
mission cover to the case. Make
sure
to remove the
two center bolts. Discard the se lf-locking nuts. as
they cannot be re-used.
NOTE
On 1997-011 models, the bo lts secur-
ing the ('O\'er are unique since the
lin -
derside of the bolt head flange is
serrated (Figure / 6). While loosen -
ing these bolts. it wiltfe el like the bolt
is stripped within the bolt hole in the
transmission case . This is no / the case
and there is no threadlo cki ng com-
po und
Oil
the bolt threads .
6B. On 1997-011 models , remove the perimeterbolts
securing the transmission cover
(A,
Figure 17) to
the casco Make sure to remove the two center bolts
(B. Figure 17).
CA UTION
Do
not
p rj' the co ver (l\vay fro m the
transmission case. The cover is vel)'
long and is relatively thin.
ff
pl}' ing
/0
release
it,
there is a \'eJ)' good
chan ce the co ver will crack and have
to be replaced (it cau be rep laced
separately).
The sealing
surface
be-
tween the two parts is large and the