Polaris 2004-2005 Sportsman 6x6, Service Manual

Page: 200 / 289

TRANSMISSION
8.2
SPECIAL TOOLS
PART NUMBER TOOL
DESCRIPTION
2871710
10” Center
Distance Tool
Torque Specifications
Transmission Case Bolts 12 ft. lbs. (16.6 Nm) . . . . .
Bell Crank Nut 12 ft. lbs. (16.6 Nm) . . . . . . . . . . . . . .
Transmission Drain Plug 14 ft. lbs. (19.3 Nm) . . . . .
Speedometer Angle Drive 11 ft. lbs. (15 Nm) . . . .
Transmission Mounting Bolts 25 ft. lbs. (34.5 Nm) . .
Drive Sprocket Bolt 17 ft. lbs. (23.5 Nm) . . . . . . . . . .
Output Shaft Bearing
Mounting Nuts 12 ft. lbs. (16.6 Nm) . . . . . . . . . . . . . .
Swing Arm Pivot Bolts 150 ft. lbs. (207.5 Nm) . . . .
LUBRICATION
NOTE: Refer to maintenance section for
transmission lubricant type and capacity.
GEAR SHIFT SELECTOR
REMOVAL
NOTE: To change fluid, remove selector box
assembly, disassemble, clean, and assemble.
1. Remove parts that interfere with access to shift
selector (seat, right side panel, and exhaust heat
shield, etc.).
2. Disconnect the two linkage rods from gear shift
selector slides.
3. Remove five bolts attaching gear shift selector to
the mounting bracket.
4. Lift gear selector out of mounting bracket and
away from frame.
GEAR SHIFT SELECTOR
DISASSEMBLY
CAUTION:
Wear eye protection during this procedure. Read
each step completely before proceeding. Essential
parts may be lost or damaged if you do not heed this
caution!
1. Clamp gear selector body lightly in a soft jawed
vice. Using a cross pattern, loosen each of the
four screws holding the gear shift selector cover
to the gear shift selector body. Loosen each
screw only a few turns, then proceed to another
screw.
NOTE: These parts are under pressure from the
internal springs.
2. Carefully pull the gear shift selector cover and rod
from the gear shift selector body.
3. Set the cover/rod assembly aside.
4. Remove the three springs from gear shift
selector.
5. Slowly tilt gear shift selector body sideways to
drain oil.
NOTE: Do not tip gear shift selector body upside
down or detent bullets and stop pin may fall out.
Check for signs of moisture in the selector body.
Inspect shift boot closely if moisture is present in
selector box.
6. Tap gear shift selector body, top down, against a
hard, smooth, flat surface to jar the dowel pin and