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Polaris SPORTSMAN 400 2003 - Page 209

Polaris SPORTSMAN 400 2003
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TRANSMISSION
8.16
12. Rotate front shaft while slowly turning housing
inward. As gear backlash is reduced to zero, the
shaft will begin to bind. At this point back off 1/4
turn.
TRANSMISSION OUTPUT
GEAR
BACKLASH
INSPECTION/
ADJUSTMENT
13. The following steps must be performed to obtain
proper front output gear backlash adjustment:
S The pinion gear must be held
securely.
S Do not lubricate the gear teeth until
backlash adjustment is complete.
Both Gears should be free of grease
and oil.
S Perform adjustment with front output
housing seal removed and end play
properly adjusted.
S Measure backlash using the
BacklashSettingTool (PN 2871695).
The measurement point is 3.875
(98.43mm) from shaft centerline.
S Set backlash at .008 - .014 (.20
-.36mm).
S Check backlash in several locations
of ring gear.
Front Gearcase
Use This Mark
Transmission
Front Output
Shaft Use
This Mark
3.875
1.875
S Backlash Setting Tool (PN 2871695
14. Install the Backlash Setting Tool (PN 2871695)
on shaft as shown. With pinion gear held
stationary, rotate output shaft back and forth,
reading the total movement of dial indicator. The
dial indicator must be positioned as shown at the
proper distance (aligned with outermost mark on
tool, and 90 to the tool surface), or indicated
backlash will be inaccurate.
S To reduce backlash, rotate housing
clockwise as viewed from front of
housing.
S To increase backlash, rotate housing
counterclockwise.
15. Torque pinch bolts to specification. Be sure pinch
plate (A) is installed. Verify backlash
measurement.
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