Transmission - Polaris SPORTSMAN 400 2003 Service Manual

MAINTENANCE
2. Clean and reinstall drain plug using a new sealing
washer.
3. Remove fill plug.
4. Add proper amount of lubricant.
5. Install fill plug. Check for leaks.
Make sure vent
is unobstructed
Fill plug
Drain Plug
TRANSMISSION GEARSHIFT
LINKAGE ADJUSTMENT,
PRELIMINARY INSPECTION
Linkage rod will rotate
1/8 -1/4 turn if rod ends
are tightened properly.
Parallel
Correctly Tightened
Jam Nut
S If shifting problems are encountered,
the transmission linkage can be
adjusted.
S
Tighten shift linkage rod end jam nuts
properly after adjustment.
should be able to rotate the linkage
rod between 1/8 and 1/4 turn after
both jam nuts are tight.
S
The

transmission

should be periodically inspected for
wear and parts replaced as required
to remove excess play from shift
linkage.
S Refer to Transmission chapter for
more information.
2.10
Drain plug
Incorrectly Tightened
Jam Nut
You
shift linkage
SHIFT LINKAGE
ADJUSTMENT
Linkage rod adjustment is necessary when
symptoms include:
S No All Wheel Drive light
S Noise on deceleration
S Inability to engage a gear
S
Excessive gear clash (noise)
S
Shift selectors moving out of desired
range
NOTE: When adjusting linkage, always adjust both
linkage rods. The adjustment of one rod can prevent
proper adjustment of the other rod.
necessary components to gain access to shift linkage
rod ends (i.e. exhaust heat shield, exhaust pipe, etc.).
Gear Selector
Low Range
Slides
Jam
Jam Nut
Nut
NOTE: Rod end orientation, rod ends are
both down.
Ill. 1
1. Inspect shift linkage tie rod ends, clevis pins, and
pivot bushings and replace if worn or damaged.
Lubricate the tie rod ends with a light aerosol
lubricant or grease.
2. Loosen all rod end adjuster jam nuts see Ill. 1.
3. Note orientation of tie rod end studs with stud up
or down. Remove both rod end studs from
transmission bell cranks.
4. Be sure idle speed is adjusted properly.
NOTE: It is important to disconnect both rod ends
from the transmission bell cranks. If one linkage rod
is incorrectly adjusted, it can affect the adjustment of
the other rod.
5. Place gear selector in neutral. Make sure the
transmission bell cranks are engaged in the
Remove