Polaris 1999 Sportsman 400 Service Manual page 272

266
c. Tighten the two ce nte r 5/16 in. holt s first ,
then the perim eter bo lts and nu ts in th ree
steps in a crisscross patt ern 1 0 the torque
spec ilica tio n listed in Tahle
J.
NOTE
On 199 7-on models, the bolt s secur-
ing the cove r are unique since the
UIl-
ders ide of the bolt head flange is
se rrated (Figure 80) . While tighten-
ing these bolts it willfeel like the bolt
is stripping the bolt hole in the trans-
miss ion case. This is not the case. Do
1I0(
apply
allY
threadlocking
co m-
pou nd to the bolt threads.
40B. On 1997-un model s, perfo rm the followin g:
a. Insta ll the peri meter 1/4 in. bolts (A , Figure
81) a
nd the two cen ter 5116 in. bo lts (B, Fig-
ure
81)
securing the tran sm issio n case
hal ves togethe r.
b. Tight en the two ce nter 5/16 in. bolt s (B,
Figu re 81 ) first, then the perim eter bolt s
(A , Fi gure 81) in three steps in a crisscross
pa ttern to the torqu e speci lieati on listed in
Table I.
4 1. At this poi nt, ch eck the tran smission opera-
tion . Ro ta te the shafts by ha nd and ch eck for
smoo th operation. Th e shafts should not have end
play, but should also not bind .
42. C lean the sea ling surfaces u f the tra nsmi s-
sion case and the inside surface of the bo tto m ac-
ces s p late with a n aeroso l parts cleaner.
43. Apply an even coat o f T hre eBond 12 15 or
eq uivalent gask et sea lant to the se a ling sur face of
the tran smissi on cas e ( Fig u re 82).
44 . Install the bott om access plate, bo lts and
loc kwas hers (Figure 83) . Tighten the bolts to the
to rqu e spec ificatio n list ed in Ta bl e 1.
CAUTION
The inte rnal con tac ts of bot h
switches are different (Fig u re 84)
and they must he reinstalled in the
correct loca tion on the transmission
case.
rf
installed inc orrectly. the
switches will be damaged.
4 5. On 1999-un mod els, perform the follow ing :
a . Refer to the F ma rk made in Disassembl y
Step 4. Ins ta ll the front gear ind icator
sw itch with a
F
(fru nt) (A, Fig ure
85) in the
C HAP T E R J"INE
fron t rece ptac le. Install the screws and tighten
sec urely.
b. Install the rear gea r ind icator swi tch (B,
Fi gu re 85) in the rea r rece ptac le. Insta ll the
screws and
tight en secur ely.
4 6. Install the drain plug and washer (Figu re 86 )
into th e base of the right case half. Tig hte n to th e
to rque spec ifica tio n list ed in Tuble 1
47. Install new o il seals as descr ibed in Chapte r
One .