Polaris 2004-2005 Sportsman 6x6, Service Manual

Page: 204 / 289

TRANSMISSION
8.6
6. Remove outer thrust washer.
Ill. 3
(2) Remove
needle bearing
Low Gear
(1) Work gear back
and forth until bearing
is exposed
7. To remove the needle bearing from the low gear,
tip transmission to point end of shaft downward.
Work gear back and forth as shown until bearing
is exposed and slide bearing out. See Ill. 3.
8. Remove the low gear and inner thrust washer.
9. Use a 1/2
″
wrench to rotate the low range
bellcrank and remove low range shift fork with dog
gear.
NOTE: High/Reverse bell crank must be in neutral to
remove low gear shift fork shaft.
10. Remove snap ring from front drive input shaft.
11. Remove output shaft and gear assembly along
with sprocket and chain, by tapping on shaft with a
soft faced hammer, from the back side of the gear
case.
12. Remove roller chain. Note position of sprockets
and gear. Stretch 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 5.05
I
.
Chain Stretch Limit
8 pitch length = 5.05
I
Maximum