Polaris 1999 Sportsman 400 Service Manual page 284

278
In stallati un
I. Install the shaft and inner bearing into the trans-
mission end of the front output housing. Push
it
in
until it stops.
NOTE
If
eitherfront output shaf t or housing
was replaced. the output shaft end
play must be measured and adjusted
prior
10
proceeding. Ref er
10
Output
S haft End Play Inspection and A d-
j ustment in this chap ter:
If
all of the
original
components
are goi ng to be
ins/ailed, end play measurement is not
neee.SSOI)' p roviding the same
number
and thickness shims are reinstalled.
2. Tum the front output housing overand install the
outer bearin g onto the shaft. Push it in until it is fully
seated in the housing.
3. Install the same number and thickness of shims
that were removed onto the shaft.
4. Install the eirelip onto the shaft.
It
may be ncces-
sary to tap the circlip into place. Make sure it is
cor-
reetly seated in the shaft groov e.
5. Install the oil seal onto the shaft.
6. Remove the protective tapefrom the front output
housing threads. Apply a liberal coa t of antiseize
compound to the threads.
CAUTION
Do not crossthread the front outp ut
housing into the transmissi on case.
7.
Slowly
screw the
front output housing onto the
transmission case by hand.
8. Use the VST 2 1/8 inch wrench (part No.
2871701 ) (A. Figure 125) and screw the froot out-
put housing in until the O-ring seal is 8 rnrn (0.31
in.) from the transmission housing, then stop.
9.
Position the front output ring gear with the
shoulder side facing the shaft. Install the gear into
the bottom access area anti onto the shan splines
and
push
it
on
until it bottoms.
10. App ly Threellond No. 1342. or equivalent.
thread locki ug compound to the bolt threads prior to
installat ion.
II. Install the nat washer. new lockwashcr and bolt
onto the shalt end.
12. Secure the front output ring gear or shalt with a
strap wrench.
CHAPTER NINE
13. Tighten the bolt to the torque specification
listed in Ta ble I.
14. Bend ooe side of the new loekwasher up
against one of the
flats
on the
bo lt.
15. Install the pinion gear assembly as follows:
a. Install the pinion gear assembl y (B. Figure
122 )
into the
transmission
case
and
mesh
it
with the output shan gear.
b. Install the pinion gear retaining plate (A, Fig-
ure 122).
e. Appl y a light coat of ThreeBo nd TB 1342.
Loetite 242, or equivalent thread loeking
compound to the screw threads priorto instal-
lation .
d. Install the lockwashers and screws and
tighten the
screws
to the torque specification
listed in Ta ble I.
16. Apply a liberal coating of Polaris All-Season
grease. or equivalent. to the front output housing
O-ring.
17. Slowly continueto screw the frontoutput hous-
ing onto the transmission case while observing the
following :