Shift Shafts Removal/Inspection/Installation - Polaris 1999 Sportsman 400 Service Manual

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274
a.
Check
the
shift
fork
fingers
for
wear or
dam-
age
(F igu re
JI6).
b
.
Chec k the shift
fork
guide
pin (A, Figure
117)
for
severe wear
or
roughne
ss.
e.
Inspect the
portion of the shaft whe
re they
ride
in the case and
cov
e
r
(B
,
figure
117). In-
stall
the
shill
fork into
the case and
cove
r.
Chec
k for smoot h ope ration.
d. Rep
lace
the
shift shaft (s)
as nece
ssary.
S
HI FT
SHAFTS
Removal/Inspection/Installation
1.
Disassembl
e
the
transmi
ssion
as descr ibed
In
this
chapter.
NOTE
The
bell
cranks
are unique and must
he
installed
ill
the
correct
location
in
the transmissio
n
case.
All
oj the
mou
nting components
are identical to
both
bell
cranks.
2.
Ma
rk
the bell
cra
nks
with an F
(fro
nt) and
R
(rear) as
shown in Fig
ure
118.
3.
Remove
the nut and washe r (A.
Figure 119)
se
-
cu
ring
the
shill shall
bell cra
nk.
4
.
Mark
the
bell
crank and the end
of the
shi ll
sha ll
with a punch so the be
ll
crank
will
be
insta lled
in the
co
rrect position during
ass
embly.
Rem ove the bell
cra
nk
(8
,
Figure
119).
5. Rem ove
the
circ
lip
a
nd was her
sec
uri ng
the
shift
shaft
into
the
transmission
case.
6.
Withdraw the
shill sha ll
(Figure 120)
from the
interior of the transm ission
case.
7.
If
necessary,
repeat
for the othe r shift shaft.
8.
Check each shift
shaft for
wear
or
damage.
9.
Remove
the
O-ring seals
and
install new ones
.
10.
Check the washer
and
circli p
for wea
r
or dam
-
age. Repl ace
them
as
necessary.
II
.
Check
the
spring
retainer for
cracks
or
damage.
If
dam aged .
replace
the
shin shaft
as
the spring
re-
ta
iner
is
not
replaceab
le.
12. Install
by
reversing
these
removal
steps
while
noting the
follow ing:
a.
A
pply
clean tra
nsm ission
o
il
to the new
Ovring
sea ls prior to
installing
the
shift
shaft
into
(he transm
ission case.
CHAPTE R I'iINE
,
b. Re
fer
to
the
mark s
mad
e
in
Step 2
and
co
r-
rectl
y
install the shift shall
into
the
correct
re-
ceptacle
in
the
transmission
cas
e.
c.
Refer to the
mark
s
mad
e
in
Step
4 and cor-
rectly a
lign the bell crank with
the
shift sha ll.
d.
Tigh
ten the
nut
sec
ure ly.
Move the
shift sha ll
bac
k and forth and check
for
smoo th opera-
tion
.
e.
Repeat
for
the other shill shaft
.

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