Polaris SPORTSMAN 400 2003 Service Manual page 211

TRANSMISSION
18. Assemble Hi/Low/Reverse
Machined (flat) side of retainer should face direction
of thrust. Sliding high/reverse engagement dog is
symmetrical and can be installed either way. The
low gear dog must face low gear.
Washer
Needle
Bearing
Retaining
Ring
Towards
Gearcase
H/L/R Shaft
Retaining
Ring
Engagement
Dog, High/Rev
Needle
Bearing
Retaining
Ring
19. Stretch silent cluster chain tight on a flat surface
and measure the length of 8 pitches in a minimum
of three places on chain.
measurement is longer than 3.0904I.
Chain Stretch Limit
8 pitch length = 3.0904I Maximum
8.18
shaft as shown.
Bearing
Retaining
Ring
Low Gear
Engagement
Dog, Low
Reverse Gear
Needle
Bearing
Retaining
Ring
High
Gear
Washer
Bearing
Replace chain if
20. Assemble the input shaft and Hi/Low/Reverse
gear cluster as shown.
21. The two shift forks can be easily identified by the
indentations. Low/Neutral shaft has 2 detents,
and Hi/Neutral/Reverse has 3 detents.
22. Install Hi/Reverse cluster in transmission as an
assembly. If necessary use a soft face hammer to
install shafts until fully seated.