Transmission Inspection - Polaris 1999 Sportsman 400 Service Manual

270
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CIIAPTER NINE
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b. lnscr t thc high /low/reverse shaft (Fig ure 89)
thro ugh the silent chain and mesh the chain
on to the gea r sprocket.
c. Carefully twist the shafts w hi le engag ing the
si lent chain and mesh ing the two gears
(Fig-
ur e 88 ).
d. Hold onto bot h shafts and slow ly rotat e them
to make sure the gears and silent chain are
properly meshed.
TRANSMISSION INSPECT ION
Transmission Cas e
1. Clean the transmission case and cover inside and
out w ith c leaning solvent. Thoroughl y dry w ith
compressed air.
2. Using a scraper, carefully remove any remai ning
sca ler resid ue from bot h cas e and cover gasket seal-
ing surfaces,
3. Th orou g hly che ck the ga sket sealing surface of
both parts. Check for go uges or nicks that may lead
to an o il leak .
4. Insp ect the ca se and cover (Figure 96) for crack s
and fractures, es pecially in the lower areas wher e
they
aTC
vu lnera ble to rock damage. Check the areas
around the stiffening ribs, around bearin g bosses
and threa ded holes for damage.
[f
da mage is fo und ,
have
it
repa ired
by
a shop spec ia lizing in the repair
of preci sio n alum inum castings o r replace the dam-
aged case and/or cove r.
5. Check the moun ting thr ead ed holes for thread
da mage, dirt or oil bui ldup . Re fer to Figures
97-100, typical. If necessary, clea n or repai r the
threads w ith a suitable size metri c tap. Coat the tap
threa ds with kerosene or an alumi num tap fluid be-
fore lise.