Polaris Outlaw 500, Service Manual

Page: 74 / 202

3.27
ENGINE
3
3. To reassemble the main shaft, install the components in the
order removed.
4. Before pressing the reverse gear onto the main shaft, heat
the reverse gear in an oil bath if desired. This will expand
and ease pressing of the gear to the specified dimension.
5. Support the mainshaft as shown with flat blocks. Press
ONLY on the reverse gear until the total width of the gear
set measures
120.4 ± .2mm (4.74 ± .008
″
) as shown.
Transmission Reassembly
NOTE: Installation of the transmission assemblies
can be facilitated by constantly rocking or moving
them to reduce binding during assembly.
NOTE: Do not to allow transmission parts to fall
from their assemblies during installation. Parts that
are out of alignment will cause improper casehalf
mating, resulting in transmission binding. Use of
assembly lube to “stick” parts together for ease of
installation is recommended.
1. Insert the output shaft assembly, minus the outer gear into
the stator side casehalve. Do not insert outer gear or shift
fork pins at this time.
2. Insert the reverse gear shaft assembly. Verify the alignment
pin (A) has seated into the casehalf.
CAUTION
This procedure requires the use of a heat source and
hydraulic press to install components. Wear the
proper protective and safety gear to prevent injury.
Main Shaft Gear Set Width
120.4 + .2 mm (4.74 + .008
″
)
A