Polaris SPORTSMAN 400 2003 Service Manual page 207

TRANSMISSION
2. Install shaft with bearing in front output housing.
Bearing
Shaft
3. Turn housing, shaft, and bearing assembly over
and install front bearing until fully seated.
4. Front output shaft end play must be measured
and adjusted if shaft or housing was replaced.
To measure end play:
Install snap ring on shaft without shims in place.
Clamp housing lightly in soft jawed vise.
8.14
Transmission
End of Housing
5. Set up a dial indicator to measure shaft end play.
FRONT OUTPUT HOUSING
(SNORKEL) INSTALLATION
6. Measured end play will be between .030² -.070².
Shims must be added between bearing and circlip
to reduce end play. To calculate proper end play,
subtract total shim thickness from end play
measured in Step 8. Add or subtract shims as
required to obtain specified end play (.000-.003²).
Remove snap ring, install shims, reinstall snap
ring. It may be necessary to tap snap ring into
place.
NOTE: Shaft should rotate freely when finished.
Confirm end play measurement with dial indicator. Do
not install front housing seal until backlash is adjusted.
Final Installed Shaft End Play
.000² - .003² (0mm - .075mm)