Transmission Gearcase Oil Seal Inspection And Replacement; Shift Selector Linkage; Checking And Preliminary Adjustment - Polaris 1999 Sportsman 400 Service Manual

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TRANSMISSION
a
.
To
reduce
backlash,
use
the
VST
2 1/8 in.
wrench
to
rotate
the
housing
clo
ckwise
as
viewed
fro
m
the front of
the
ho
using.
b.
To
increase backlash,
use the VST
2 1/8
in.
wre nch
to rota
te
the
hou
sing
counterclock-
wise
as viewed from
the front
of
the
ho
usin g.
8.
Repeat
Steps 4-6
and
recheck
backlash .
If still
not w
ithin speci ficatio n,
repeat
Step 7 until correct.
281
9. Tight en
the pin
ch
bolt
s
(Figure
131)
secure ly.
10. Rech eck back lash
and
rea
dju
st
if
nec essary.
I
I.
Remove
both
spec
ial
tools
from
the
output
shaft,
TRA
NSMISSIO N
GEARCASE
OIL SEA L INSPE CTION
AND
REP
LACEMENT
NOTE
It
is
reco mmended tha t
the oil
seals
be
replaced eve!}' time
the transmission
is disassembled.
Ins pec t th
e o
il sea
ls
in the tra
nsm ission
case (Fig-
ure 135
, typi
cal)
and cove r.
Refer to
Figure 136
and
F
ig ur e
137. Check
for
nicks,
hardness
or
dete-
rioration.
Replace the
oil
seals
as described
in
C
hapter One.
SHIFT
SELECTOR
LINKAGE
Adju
st
the shift
linkage as the first
step
to
correc t
transmi
ssion
or shifting
problems.
Shit! link
age adjustm ent is nece ssary
wh
en
the
follo
w ing sy
mptoms
are ev
iden t:
1.
Wh
ene
ver the
transm
issio n ha
s bee
n
removed
and
installed.
2.
T
he
All
-Whee
l
Dri
ve light w
ill not illuminate
.
3.
No ise
on
deceleration
.
4. Inabi lity
to engage any gear.
S.
Excess
ive
gea
r cla
sh
when
shifting
.
6.
Shift se lector mo
vi ng o
ut
of
range.
A
lways check
the
adj
ustment
of
both
control rod
s
at
the sa
me tim
e.
The adj ustment
of one
rod
can pre-
vent
pro
per
adjust ment
of
the
other
rod
.
T
he
high
range
/re
verse rod
is
loca
ted
on
the
outer
se
lecto r
slide
and
the
low range rod
is located
on
the
inner
se
lec
tor slide
as
shown
in
Figure
138.
C
hecki ng and Prelimi nary Adjustment
I
. Rem ove the
scat and
rear
fende
r
as
described in
C
hapter Fiftee n.
2.
Befor e
adjusting
the
shift contro l rods, check for
w
ear o
r
im
pro per insta llation
as
follow
s:
a
. C
heck each
shift
contro
l
rod
where it
attaches
to the
gear selector
slides for
looseness
(Fig-
ure 139)
.
Mak
e
sure
the
nut
is
tig
ht
and
that
rod end
s
are not
worn.
II

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