Transmission Case Assembly - Polaris 1999 Sportsman 400 Service Manual

===.-8
T RA~S'\IlSSI01':
®
259
Transmission Case Assemb ly
Refe r
10
Figure 13.
I.
Install
OC\V
oil sea ls in the transmission case as
de scribed in this cha pter,
2. App ly clean tran smi ssion oil to all slid ing parts.
to the bearings and to the bearing receptacles in the
transmission casco
3. If removed . perform the follow ing:
3 .
Install the pinion gear assembl y (8 , Fig ure
45 ) into the transmission case .
b. lnstall rhc pinion gear retaining plate (A. Fig-
ure 45 ).
e. App ly a light coat of Thrcellond 1'81342.
Loctit c 24 2. or equi valent thread locking
compound to the screwthreadspriorto insta l-
lation.
d. Install the loekwa she rs a nd screws and
tighten the screws to the torque spec ification
listed in Ta ble I.
4. If the two sha fts have been separated from each
oth er. co rrec tly assemble the input sha ft and
hig h/low/reverse shaft and thc silent cha in (A. Fig -
ure 46).
5. Co rrectly install the high/reve rse shift fork onto
the high/reverse gear engagement dog on the shaft
(B. Fig u re 46 ).
6. Correctly position the assembled shafts, silent
chain and shill fork into the transmi ssio n case ( Fig-
u re 47) . Correc tly locate the shift fork pin into the
high/reverse shift shaft fingers and spring (F igure
48).
7. Align the shafts w ith the bearings in the case and
press the sha fts into place. Carefully tap on the shaft
ends (F igure 49) with a so il-faced mallet to ensure
the sh afts an d shift fork shaft are comp letely seated
in the transm ission case bearings.