Gear Shafts And Shift Forks - Polaris 1999 Sportsman 400 Service Manual

TRANSMISSION
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6. On 1999-011 mod els.
if
necessary. remove the
screws sec uring the inter lock bra cket (F igure 101).
Rem ove the bracket, two pins and the spring.
7. Inspe ct the oi l detl ector (Figure (02) for hard-
ness or damage. Make sure the oil ho le (F igu re
(03)
is
open. Clean ont if necessary.
Gear Sha fts a nd Shift Forks
Clean and inspe ct the shaft assemblies prior to
disassembling them. Place the assembled shaft into
a large can or plastic bucke t and thoroughly clean
w ith a petro leum-based solvent such as kerosene
and a stiff'bru sh . Dr y wi th co mpressed
air or let it sit
on rags to dri p dry. Repeat for the other shaft assem-
blies.
I. After c lea ning. visua lly inspe ct the com ponents
of each assemb ly (Figu re 1(4)
for
exce ssi ve wear,
An y buns, pittin g or ro ughn ess on the teeth of a
gear
will cause wea r on
the mating gea r. Minor
roug hness can be c leaned up with an oilstone, but
there is little point in attemp ting to remove dee p
scars.