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Polaris SPORTSMAN 400 2003 - Page 211

Polaris SPORTSMAN 400 2003
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TRANSMISSION
8.18
18. Assemble Hi/Low/Reverse shaft as shown.
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.
Low Gear
Reverse Gear
High
Gear
H/L/R Shaft
Bearing
Washer
Engagement
Dog, Low
Bearing
Engagement
Dog, High/Rev
Needle
Bearing
Washer
Needle
Bearing
Retaining
Ring
Retaining
Ring
Retaining
Ring
Needle
Bearing
Retaining
Ring
Retaining
Ring
Towards
Gearcase
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. Replace chain if
measurement is longer than 3.0904I.
Chain Stretch Limit
8 pitch length = 3.0904I Maximum
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.
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