Polaris 2004-2005 Sportsman 6x6, Service Manual

Page: 202 / 289

TRANSMISSION
8.4
CAUTION: Too much oil could cause the selector to
hydrolock. Be sure the selector box is level when
adding oil.
5. Wipe gear selector dry, clean surfaces of cover
and selector box with Loctite
t
Primer T and place
a bead of Loctite
t
518 Gasket Eliminator ( PN
2870587 ) or Crankcase Sealant ( PN 2871557 )
completely around the edge of the gear shift
selector body.
6. Carefully reattach cover/rod assembly to gear
shift selector body. Make sure slides are in
neutral, or butterfly may be damaged.
7. Torque cover screws to 12 ft. lbs. (17 Nm).
GEAR SHIFT SELECTOR
INSTALLATION
1. Place gear shift selector back into the mounting
bracket and replace five bolts.
2. Reconnect linkage rods to gear shift selector
slides. Adjust as required. See linkage
adjustment procedures.
3. Replace remaining parts.
BOOT REPLACEMENT
NOTE: If moisture is found in the gear shift selector
the boot should be replaced.
1. Using a slotted screwdriver, remove cap from
gear shift knob.
2. Remove torx screw securing knob to selector rod.
3. Pull selector knob off selector rod.
4. Remove band clamp on rubber boot.
5. Slide boot off selector rod and replace with a new
one.
6. Apply RTV silicone to selector rod to seal top of
boot.
7. Place band clamp in position and tighten using CV
boot clamp pliers.
8. Replace shift knob, securing it to selector rod with
screw removed in Step 2.
9. Push shift knob cover back into place. Allow
approximately 12 hours for RTV silicone to cure.
Knob
Screw
Cap
Clamp
Boot
Seal with
RTV silicone