Polaris 1999 Sportsman 400 Service Manual page 301

FRONT DRIVE SYSTE M
295
a. Roller-to-roll er cage sliding surface rough-
ness or int erference .
b. Roller cage- to-ea rn mating surface, including
the cam shoulder and cage-to-earn matin g
surfaces for roughness or interference.
c. Retain er spring tension that is insuffici ent to
puJl the rollers back into the roller cage in the
ne utra l posit ion .
lnstallation
Improper installation and adj ustme nt of the
I-I
i
liard clutch can result in a dangerous lack ofvchi-
ele contro l. The dri ve clutches must be co rrectly in-
stalled for the front drive to function properly.
NOTE
The
caUl
on some models is marked L
or
R
and must be install ed on the cor-
rect side. lf the cam is not marked, the
cam can he ins talled on either side.
I. Test the ope ration of the Hilla rd clutch prior to
installing it on the front axle.
2. Usc a depth gauge or a stra ightedge and feeler ..._ ..
gauge to mea sure the dista nce from the outer pole
(se al sleeve) to the inne r pole as shown in Figure t-:=;.,
16. Meas ure the pole ga p in at least three location s
and co mpare with the spec ification in Table 2.
3. If the pole gap meas ured is incorrect. move the
outer magnet pol
e by
tappi ng the seal sleeve.
4. Install the arma ture plate (Figu re 17) into the
sam e loca tion
us
noted
in
Removal Step
14 (Figure
10).
5. Install the spacer (Figur e 9 ) and push it on until
it stops again st the
axle beari ng.
6. Apply the reco mmended lubricant to the Hillard
clut ch assembly,
7. Position the Hillard clutch as shown in Figure
18 and install it. Push it ou until it stops (F igure 19).
8. Be sure the tabs of the armature plate are en-
gaged wit h the holes in the ro ller cage. as show n in
Figure 20.
9. Install the inner bearing (Figure 21).
10. Coat the whee l hub sea l (Fi gure 22) with
grease, then install the whee l hub ove r
the
c lutch
and on to the front ax le (F igure 23). Be carefu l not
to dama ge the sea l,
II . Install the outer bearing ( Figu re 24) and press
it into the front hub until it is correctly seated in the
hub o uter rac e (Figure 25).