Polaris Sportsman 400 Service Manual page 293

TRANSMISSION
TRANSMISSION OUTPUT GEAR BACKLASH INSPECTION/
ADJUSTMENT
13. The following steps must be performed to obtain
proper front output gear backlash adjustment:
S
The pinion gear must be held securely.
S Do not lubricate the gear teeth until backlash ad-
justment is complete. Both Gears should be free
of grease and oil.
S
Perform adjustment with front output housing
seal removed and end play properly adjusted.
S
Measure backlash using tool (PN 2871695).
The measurement point is 3.875" (98.43mm)
from shaft centerline.
S Set backlash at .008" - .014" (.20 -.36mm).
S
Check backlash in several locations of ring gear.
14. Install special tool (PN 2871695) on shaft as shown.
With pinion gear held stationary, rotate output shaft
back and forth, reading the total movement of dial
indicator. The dial indicator must be positioned as
shown at the proper distance (aligned with
outermost mark on tool, and 90° to the tool surface),
or indicated backlash will be inaccurate.
S To reduce backlash, rotate housing clockwise as
viewed from front of housing.
S
To increase backlash, rotate housing counter-
clockwise.
15. Torque pinch bolts to specification. Be sure pinch
plate (A) is installed. Verify backlash measurement.
8.24
- projex@inbox.lv -
A
Front Gearcase
Transmission
Use This Mark
Front Output
Shaft Use
This Mark
1.875"
3.875"