Transmission Removal/Installation - Polaris 1999 Sportsman 400 Service Manual

250
CIIAPTEH NINE
tech nique: Open the new c irel ip with a pair of
cirel ip pliers wh ile holding the back of the c irel ip
with a pair of pliers ( Figu re 2). Then slide the
circlip down the sha ft and seat it into its correct
transmi ssion groove . This tech nique ca n also be
used to rem ove the circ lips from a sha ft once they
are free from their grooves .
TRANSMISSION
Rem ovul/I nstal la lion
7. Rem ove the outer cover, drive be lt, drive pulley.
driven pulley and inner cover as described in Chap-
ter Eig ht.
8. On 1996- 1998 mod els. discon nect the speedom-
eter cab le from the le ft side of the tran smi ssion case
cover.
9. Loo sen the rear wheel lug nuts on both rear
whee ls.
10. Raise the vehic le and support
it on woo
den
block s under the foot rest and fram e with the rear
whee ls ofT the ground.
II. Remove both rem whee ls as described in Chap-
ter Thirteen .
12. Rem ove the transmission output shaft brake
caliper and brak e disc (Figure 3) as described in
Chapter Fourteen.
It
is not necessary to disconnect
the brake lines from the caliper. Move the cal iper
I.
Place the ATV on a level surface and set the
parking brake. Block the front whee ls to keep it
0
from rolling in eith er directi on .
\::.J
2. Rem ove the scat, the front and rear fenders as
described in Chapter Fifteen.
3. Remove the carburetor as described in Chapter
Six.
4. Remove the air filter air box as de sc ribed in
Chapter Six.
5. Remove the ex haust pipe and muffl er as de -
sc ribed in Chapter Four.
6. Drain the tran sm issio n oil as described in Cha p-
ter Tbree.
CAUTION
Do not lose or damage the spacer
washers located behind the driven
p ulley. These spacers are used to ad-
j ust the p ulley offset ami must be rein -
stalled.