Polaris 1999 Sportsman 400 Service Manual page 278

272
2. Inspect the engagement dog s (A, Figure 105) on
the gears. If any are chipped, worn, rounded or
missing. the affected gearmust be replaced.
3. Inspect the engage ment dogs (B, Figu re 105). If
any are chipped. worn, rounded or missing, the af-
fected engagement dog must be replaced.
4. Rotate the transmission bearing(s) (C, Figure
105) on all three shafts by hand. Check for rough-
ness, noise and rad ial play. Replace any bearing that
is questionab le.
SA. If the transmission shafts arc satisfactory and
are not goi ng to be d isassembled. apply clean trans-
mission gear lubricant to all components and rein-
stall them in the transmission cases as described in
this chapter.
SIl. If the shafts ha ve been disa sse mb led, cont inue
with this procedur e.
6. Clean and carefu lly inspect all gea rs for burrs,
chips or roughness on the tee th (Figu re 106).
7. Inspect both sides of the gea r engagement dogs
(A, Figure 107). If the edge s o f the eng agemen t
dogs are rounded or chipped, replace the gear.
8. Inspect the engagement dogs inner splines (B,
Figure 107) for
wear
or damage. If any of the
splines are damaged. replace the engagement
dog(s).
9, Check the needle
bearings to r
severe wear,
cracks or other da mage . Install the needle bearing
into the gear (Figu re 108) and rotate it inside the
gear. It must rolate freely. Replace as necessary.
10. Inspect the input sha ll as follows:
a. Inspect the splines (F igur e 109) for wear or
dama ge.
b. Inspect the bea rings (A, Fig u re 91). They
must
tum
smoothly; if necessary.
replace
them as describ ed in C hapter One.
c. Inspect the
silent
chain gear sprockets (B,
Figure 9
1) for wear or damage. If damaged.
replace the shaft as well as thc silent chain.
NOTE
There
lire
11 0
service limit specificu-
lions f or
the silent and drive
chains.
I I . Inspect the high/ iowlreverse gear shaft as
1'01-
1 00\'s:
a. Check the circlip
grooves
in the shaft for
cracks or damage. The groove should be
square to prevent the circlip from coming out.
C HA PT E R N INE