Troubleshooting; Troubleshooting Checklist - Polaris SPORTSMAN 400 2003 Service Manual

Seal Installation Tool
Rear Output Seal Driver (PN 2871698)
Rear Driveshaft Seal Guide (PN 2871699)
36. Apply grease to the lip of a new input shaft seal.
Install the seal, being careful to work the lip of the
seal over the step in the shaft before using the
Bearing Seal Driver (PN 2871282). Install the
seal flush with transmission housing.
Bearing Seal Driver:
(PN 2871282)
37. Install gear indicator switches. Apply Loctitet
242 (PN 2871949) to threads of switch screws
and torque to 13-16 in. lbs. (1.5-1.9 Nm).

TROUBLESHOOTING

CHECKLIST
Check the following items when shifting difficulty is
encountered.
S Idle speed adjustment
S Transmission oil type/quality
S
Transmission torque stop adjustment
S
Engine torque stop adjustment
S
Drive belt deflection
S
Loose fasteners on rod ends
S Loose fasteners on selector box
S Worn rod ends, clevis pins, or pivot arm
bushings
S Linkage rod adjustment and rod end
positioning
S Shift selector rail travel
S *Worn, broken or damaged internal
transmission components
NOTE: To determine if shifting difficulty or problem is
caused by an internal transmission problem, isolate
the transmission by disconnecting linkage rods from
transmission bellcranks. Manually select each gear
range at the transmission bellcrank, and test ride
vehicle. If it functions properly, the problem is outside
the transmission.
NOTE: If transmission
disassemble transmission and inspect all gear dogs
for wear (rounding), damage. Inspect all bearings for
wear.
TRANSMISSION
problem remains,
8.21