Polaris 1999 Sportsman 400 Service Manual page 293

TRA NSMISSION
16. Remove the gears hift se lector bod y from the
vise and install it in the fram e as described in this
chapter.
Gea rshift Sele ct or
(2000 M odels)
Disassembly
Refer to Figu re 149.
1. Remove the gearshift se lector as descr ibed
It1
this chapter.
2 . Place the gearshift se lector bod y in a vise wit h
so ft j aws .
3. Remove the cap from the shift knob .
4 . Remove the Torx screw securing the shift knob
to the shift selector rod. Remo ve the sh ill knob .
5. Remove the wire strap securing the rubber boot
to the shift se lect rod and cover. Disca rd the wire
strap.
6. Remove the four screws securing the rubber
boot/cover to the lever body.
7. Slide the rubber boot/cover up and off the shift
se lector rod.
8. Carefully pull the shift selector rod asse mbly
stra ight lip and off the body to avo id damage to the
selector slides.
NOTE
In Step 9, do not turn the hody upside
down to drain the oil as the detent bul-
lets and stop p in may / all out.
9. Remove the body from the vise, t ilt it sideways
over a pan and drain out the oil.
10. Check for signs of mo isture within the body. If
moisture is present, replace the rubb er boot as pre-
viously described.
I I. Tum the body upside down over anot her pan on
the work surface . Tap the body onto the pan to dis-
lodge the stop pin, centering spring and two detent
springs and pins. Make sure to remove both de tent
springs and pins and the stop pin and spring .
NOTE
The left side low rang e selector slide
has l\vo notches. The right side
high/reverse selector slide
has
three
notches. The selector slides must be
reinstalled into the correct recep tacle
in the body.
287
12. Withdra w both selector slides from the body.
13. Inspec t all parts as described in this chapter.
As sem bly
Refer to Figure 149.
I.
Coat each se lector slide O-ri ng with clea n en-
gine oil.
2. Care fu lly install the le tt side low range selector
slide (two notches) into the correc t receptacle in the
body and index it into the interlock butterfly. Do not
damage the O-r ing during installation.
3. Carefully install the right side low range se lector
slide (three notches) into the correct receptacle in
the body. Do not damage the O-ring during installa-
tion.
4. Install the spring and stop pin into the body.
5. Install the two detent springs and detents into the
body.
6. Place the gearshift selector body in a vise with
soft jaws. Locate the body so it is level.
CAUTION
Do no t add mo re oil than specified, as
this cou ld cause the gears hi]! selector
to hydrolock while shifting.
7. Add Polar is I OW-40 All-S eason Synthetic mo-
tor oil to the body until the lower half oft he selector
slides are covered.
8. Move the se lecto r slides to the NEU T RAL posi-
tion .
9. Ca refully install the shift selector rod asse mbly
straight down into the body and index the end into
the selector slides .
10. Apply a light coa t of Three Bond 1215 gasket
sea ler to the body mating sur face.
II . Slide the rubber boot/cover down onto the shift
selector rod.
12. Install the screws , Tighten the screws a few
turns at a tim e in a crisscross pattern to the torque
specificatio n
listed in Table I.
13 . Insta ll a new wire strap securing the rubb er
boot to the shift se lect rod and cove r.
14. Install the shift knob and Torx screw. Tighten
the screw secure ly.
15. Install the cap onto the shift knob.
16. Remove the gears h ift se lector bod y from the
vise and install it in the frame as described in this
chapter.
II