Polaris 2005 SPORTSMAN 500 Servise Manual page 229

6. Install the output gear assembly. Be sure to
properly mesh the snorkel shaft bevel gear with
the output bevel gear (A). Install the 4 torx screws
(B) to secure the output gear assembly into place.
Torque screws to 8--12 ft.lbs. (11--16 Nm).
NOTICE! : It is important to set zero lash between
the output gear and the snorkel shaft gear. If
there is binding or excess lash, tighten or loosen
the snorkel shaft until there is zero lash.
A
B
8--12 ft.lbs.
TRANSMISSION FRONT
OUTPUT SHAFT GEAR
BACKLASH SETTING
PROCEDURE
7. The following steps must be performed to obtain
proper front output gear backlash adjustment:
As completed in Step 6, make sure the
S
snorkel gear and output bevel gear are lightly
seated or meshing, so there is zero lash. Do
not overtighten.
Before turning the snorkel tube, look down
S
into the gearcase at the snorkel lock screw
hole opening (Photo 2). Now slowly rotate the
snorkel tube counterclockwise (Photo 3),
while counting the number of notches as you
rotate the snorkel tube. Rotate the snorkel
tube to the 7th notch (Photo 1 & 2) using a
2 3/8" wrench.
Now check the output shaft gear backlash
S
again by feel. If the output shaft appears to
be to tight, rotate the snorkel shaft
counterclockwise to the next notch or 8th
notch.
TRANSMISSION
Photo For Reference Only! Snorkel
Shaft is installed in this procedure.
Photo 1
Count 7 notches of snorkel tube
through snorkel lock screw hole
Photo 2
Rotate snorkel counterclockwise --
7 notches on snorkel as reference
Photo 3
Count 7 notches
on snorkel tube
8.15