Front Output Shaft - Polaris 1999 Sportsman 400 Service Manual

T RANS MISS ION 275
FRONT OU T PUT SHAFT
Do not re move th e fro nt o utpu t sha ft assembly
unless necessary. If remo ved, spec ial tools are
nec essary during install at ion a nd two insp ection
and adj ustme nt procedures are required to check
Output Sha(i Elld Play
and
Ol/IPII I Shaft Gear
Backlash,
It is recomme nded that both o f the se proce-
dure s be performed by a Pola ris deal er shi p d ue to
the specia l tool s and expe rtise req ui red .
Rem o va l
Refer to F ig ure 12 1.
1. Rem ove a ll transmissi on com po nents from the
case as prev ious ly described in this chapter.
2. Remove the screws and lockwashers securing
the pinion gear retaining plate (A, F ig ure 122 ).
3. Withdraw the pin ion gear assembl y (H. Fig u re
122)
from
the transmission case half.
4. Use a perma nent mar kin g pen to mak e an a lign- •
ment mark between the fro nt output housing and the
tran smission case (Fi gu re 123) . Thi s w ill ens ure
correct alignme nt duri ng installation .
5. Loosen the out put hous ing pinch bolts (F igurc
124).
C ·1UTJON
Do
not try to completely
tll1ScrelV
the
front output housing in substep c.
6. Usc the VST 2
1i8
inch wre nc h (part No .
287 170 I ) (A , Fig u re 125 ) to partia lly unscrew the
front output housing from the transmission case un-
til the O- ring is exposed by 13 mm (0 .5 in.).
N OTE
The bottom access cuver had a seal-
ant app lied to it during assembly. and
is difficult to loosen/rom the bottom
of the transmission case.
7. Rem ove the bo lts and Iockw ashers securing the
bottom access cover (F igure 126). Tap around the
perimeter o f the cove r to break the sealant loose,
then remove the cover.
8. Secure the front output ring gear (A. Figu re 127)
or shaft with a strap wrench.
9. Straig hten the lock wash er tab away from the
bolt head.