Transmission Output Gear Backlash Adjustment - Polaris Magnum 2x4 Service Manual

TRANSMISSION SERVICE
Type IV, Shaft Drive Transmission
Shaft Drive Transmission Assembly, Cant.
30. Rotate front shaft while slowly turning housing
inward. As gear backlash is reduced to zero, the
shaft will begin to bind. At this point back off 1/4 turn.
Transmission Output Gear Backlash Adjustment
NOTE: This procedure can be performed with transmis-
sion installed in frame.
31. The following steps must be performed to obtain
proper front output gear backlash adjustment:
The pinion gear must be held securely.
Do not lubricate the gear teeth until backlash ad-
justment is complete. Both gears must be free
of grease and oil.
Perform adjustment with front output housing
seal removed.
Measure backlash using tool (PN 2871695).
The measurement point is 3.875/1 (98.43mm)
from shaft centerline.
Adjust backlash to .008" - .014" (.20 -.36mm).
• Check backlash in several locations of ring gear.
32. 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 backlash will be incorrect.
To reduce backlash rotate housing clockwise as
viewed from front of housing.
To increase backlash rotate housing counter-
clockwise.
33. Torque pinch bolts. Recheck backlash.
1996 Models: Make sure pinch plate is in place before
tightening.
10/96 8.34
Input Shaft
Front Gearcase Transmission
Use This Mark Front Output
Shaft Use
This Mark
.....---- 3.875"
------JIIoI
Polaris Industries Inc.