Transmission Shafts Disassembly; Transmission Shafts Assembly - Polaris 1999 Sportsman 400 Service Manual

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TRANS,\1!SSION
267
Transmission Shafts
Disass
embly
Refer
to Figure 87.
I. To
se
parate
the
input
sha lt tram
the
high/low/re-
verse
shaft, perform
the following:
a.
Ca
refu
lly
tw
ist
the shafts (Figu r e 88)
disen-
gag
ing
the
silent
chain from the gear
sprocket on
the high/low/reverse
shaft.
b.
Slide
the high/low /reve rse
shaft
out of
the
chain (Figure 89) and
remove
it.
c
.
Remo ve
the
silent chain from
the
input
shaft
gea
r
sproc ket
(Figure
90)
.
2. Th
e
inp
ut
shaft
ca nnot
be
disassembled
with
the
exception
of
the
bearing s.
If the beari
ngs
(A,
Fig-
u
re
9
1)
are defective,
rep lace them as
described
in
Cha pter On
e.
3.
To
disassem ble the high/low/re verse
shaft (F
ig-
u
re
92
),
perform the following:
a. Use
a
tw
o-
or
three-jaw
puller
to remo ve
the
bear
ing
(A) from the right
end
of
the
shaft.
b.
Remove
the
eircl ip
and
slide
off
the
thrust
washer,
e.
Slide off the
high gea
r
(B)
, need le
beari
ng
and
washer.
d.
Slide
off the high/reverse engagement dog
(C).
c. Remove
the
ci
rclip and slide
o
ff
the washer,
f. Slide off
the reverse
gear
(D),
needle
beari
ng
and
washer.
4. To
d
isassemb le
the center dri
ve
shaft,
slide off
the
output gea r
(F
igu r e 93). If neces
sary,
use
a
two -
or
three-jaw puller to remo ve the hearing
(Figure
94
)
from the left
end
of
the shaft.
5. Inspect
the
shaft co
mpone
nts as de
scribed
un-
der Transmission
Inspec tion
in
this chapter.
1.
If
remo ved ,
install the
bearing
(Figu re 94)
onto
the
left end
of
the center dri
ve
shaft.
Insta
ll
the
out-
put
gea
r (Figu
re
93) onto
the
shaft.
2.
To ass
emble
the
highll ow/rcverse
shaft (Figu
re
92),
perform
the follo
wi
ng
:
a.
Slide on
the
wa
sher and
the needle bearing.
b.
Position
the
reverse gea
r
with
the
ge
ar dogs
side go ing on last and
slide the
gear
(D)
o
nto
the
sha ft
and
onto the needle
bearing.
II

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