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Polaris SPORTSMAN 400 2003 - Page 208

Polaris SPORTSMAN 400 2003
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TRANSMISSION
8.15
7. Remove electrical tape and apply anti-seize
compound to the threads of the front output
housing.
8. Screw in housing until O-ring is approximately
1/4 (8mm) from transmission housing.
9. Install front output ring gear, washer, and
retaining bolt with a new lock plate. Hold shaft
with strap wrench and tighten retaining bolt.
Clean threads of bolt and shaft with Loctitet
Primer N. Apply Loctitet 242 (PN 2871949) to
retaining bolt threads. Torque bolt to specification
and bend lock plate against hexagonal portion of
bolt.
Ring Gear Retaining Bolt
17 - 20 ft. lbs. (24-27 Nm)
Apply Loctitet 242 (PN 2871949)
10. Install pinion gear assembly and retaining plate.
Use Loctitet Primer N on threads and housing.
Apply Loctitet 242 (PN 2871949) to bolts and
torque to specification.
Pinion Gear Retainer Screws:
17 - 20 ft. lbs. (24-27 Nm)
Apply Loctitet 242 (PN 2871949)
FRONT OUTPUT HOUSING
(SNORKEL)
BACKLASH
ADJUSTMENT
11. Lubricate front housing O-ring thoroughly with
Polaris All Season grease. Continue to screw
front housing in, making sure O-ring enters
housing without damage. Be sure ring and pinion
gear teeth mesh properly.
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